Global wind turbine manufacturer Vestas (Aarhus, Denmark) announced on Jan. 20 that it plans to produce zero-waste wind turbines by 2040, as part of its company focus on sustainability.
Vestas says that it is the first turbine manufacturer to commit to zero-waste wind turbines, and that this process will involve running a value chain that generates no waste materials. This will be achieved by developing and implementing a new waste-management strategy, introducing a circular economy approach in the different phases of the value chain: design, production, service and end-of-life. Vestas plans to present this strategy within the next two years.
According to Vestas, waste generated from turbine blades is estimated to be around 43 million metric tonnes accumulated by 2050. Reporting that the global wind energy market set to grow by an average of 3% per year in the coming decade, Vestas says it is mitigating its own environmental impact by committing to eliminate waste across its value chain. Today, Vestas reports that its wind turbines are on average 85% recyclable, but that wind turbine blades currently comprise non-recyclable composite materials.
Vestas will consider all aspects of the turbine lifecycle, aimed at improving the recyclability rate of blades and nacelles. As a first step, Vestas will be focusing on improving the recyclability of all wind turbine blades. Incremental targets will be introduced to increase the recyclability rate of blades from 44% today, to 50% by 2025, and to 55% by 2030. This includes several initiatives designed to address the handling of existing blades after decommissioning, Vestas says. These will cover new recycling technologies that are optimal for composite waste, such as glass fiber recycling and plastic parts recovery. Vestas says it will also be implementing a new process around blade decommissioning, providing support to customers on how to decrease the amount of waste material being sent to landfill.
“Establishing such an ambitious goal for waste reduction is paramount to ensuring a better world for future generations,” says Anders Vedel, Vestas executive vice president of Vestas Power Solutions. “Leading the wind industry is not enough to combat the global challenges we face today. If we are to spearhead the energy transition, we must be an example for doing so in the most sustainable way, and this involves making sustainability part of everything we do.”
“As the world’s largest supplier of wind energy, Vestas has a responsibility to eliminate waste across its value chain,” says Tommy Rahbek Nielsen, Vestas interim chief operations officer. “Wind energy will continue to grow rapidly, therefore the time for a conservative approach is behind us. I am proud to be part of an organization that is making sustainability an integral component in all business operations.”
Source: Composites World
The Bloodhound LSR project, which plans in 2020 to break the world land speed record of 763.035 miles per hour, reported on Nov. 11 that in its series of high-speed testing in South Africa, it has taken the Rolls-Royce EJ200 jet-powered car up to 501 miles per hour.
The Bloodhound LSR tests are being conducted on a 10-mile-long dirt track at the Hakskeen Pan on the Northern Cape of South Africa and has involved a series of progressively faster runs beginning in October 2019. The test driver is Andy Green, the driver of Thrust SSC, which set the current land-speed record in 1997.
In a blog post that summarizes the testing, Green says the surface of Hakskeen Pan, although flat, is covered with stones and bisected by an old causeway road, which was removed and graded for the test runs. Green achieved 450 miles per hour on Nov. 1, and then a peak speed of 501 miles per hour on Nov. 6.
Green says the car is standing up well to the rigors of high-speed testing, with only the bottom edges of the rear suspension, known as the rear deltas, having suffered wear and tear. He also describes the challenges of steering a a long vehicle at high speeds and the effect of the brake chute on the car’s aerodynamics.
Bloodhound LSR will be tested for a couple more weeks and then return in 2020 for the attempt to break the land speed record, powered by the Rolls-Royce engine and a rocket. This Facebook video shows Bloodhound LSR during one of its runs.
Bloodhound LSR started life in 2007 as Bloodhound SSC, but could not maintain needed funding and entered administration in 2018. Ian Warhurst purchased the bloodhound and assets in December 2018 and thus restarted the effort to break the land speed record. Bloodhound LSR is now owned and managed by Grafton LSR Ltd. (Berkeley, U.K.). CompositesWorld wrote about Bloodhound in this 2015 story about the composite air brakes on the vehicle.
Source | Composites World
Scott Bader and Shape Corp have worked in partnership to produce the automotive industry’s first curved, multi-hollow pultruded carbon fibre bumper beam for the newly unveiled 2020 Chevrolet Corvette Stingray.
The pultruded bumper beam is manufactured using Scott Bader’s Crestapol urethane acrylate resins. Crestapol resins were chosen due to their market leading strength, toughness and lightweight properties as well as their ease of use and excellent bonding with carbon fibres. The substantial weight saving while maintaining strength was a particularly appealing property when compared with more traditional materials. The urethane acrylate resins have produced a superior lightweight carbon fibre component that helps to protect the rear and expanded boot of the Corvette.
This is a significant project for Scott Bader as it’s the first ever pultruded part within an automotive application. Scott Bader’s technical team have been working in collaboration with Shape Corp engineers since July of 2016, overcoming various barriers to get to this point. The success of the project showcases the superior performance composite parts can bring to the automotive industry.
“The attribute that we like the most about the Crestapol resin is the ability to withstand the temperatures of the E-coat paint process. This part is assembled in body, so the part gets dipped and exposed to elevated temperatures. The Crestapol resin provided a solution against other alternatives without compromising performance or process speeds. In addition, this part has impact requirements, so resin selection played an important part in meeting all of the challenging requirements,” says Toby Jacobson, Plastic Materials & Process Manager, Advanced Product Development at Shape Corp.
Scott Bader’s involvement in the project doesn’t stop there. As well as the Crestapol resins used to manufacture the bumper beam, Scott Bader’s Crestabond adhesives are used to bond the bumper beam to the e-coated steel structure at the rear of the car. Several structural adhesives were tested to find the best combination of strength and toughness to meet the crash, impact and durability requirements necessary to achieve Chevrolet’s standards. Scott Bader’s Crestabond M7-05 was successfully chosen due to its ability to bond under the high temperature test protocol.
Vicki Holt, president and CEO of Protolabs (Maple Plain, Minn.), keynoted the General Session of CAMX 2019 yesterday morning and explored for the audience her company’s keys to success as a leading source of fully digital rapid prototyping and on-demand manufacturing services.
Holt, who has a background in composite materials via work at Montsanto and PPG, has led Protolabs for the last six years and has helped the company grow to 12 global locations providing fast-turnaround manufacturing services via CNC, injection molding, additive manufacturing and sheet metal fabrication. Protolabs works entirely via an e-commerce portal and converts CAD-based designs into finished parts in just a matter of days.
During her presentation, Holt outlined six lessons she has learned at Protolabs. First, she said, iteration and prototyping are most effective when deployed quickly. “If there’s a big problem to solve, you can get a lot of value solving it quickly, she said.”
Second, she said, is that solutions require access to employees with diverse backgrounds who are willing and able to re-think and question assumptions, and in the process find new ways of meeting goals.
Third, I learned “how important it is to get a minimal viable product out into the marketplace quickly so that you can learn and iterate.” That is, the sooner a product is on the market, the sooner you can evaluate its fit and effectiveness.
Fourth, Holt said, is to stay true to your core – identify the habits and strategies that differentiate your business and continually fine-tune and optimize those. “Stay true to that source of differentiation,” she said.
Fifth, timing is everything, she said. At Protolabs, the birth of B2B commerce occurred nearly simultaneously with the birth of the company in 1999, and that became the foundation from which all of the company’s products and services grew.
Sixth, Holt said, “How we work makes a big difference.” Protolabs has a highly defined culture based on collaboration, change, multifunctionalism and learning. “We take culture very, very seriously,” she said. “If it gets away from us, we know that we will not become the company that we want to become.”
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Source | Composites World
SAERTEX (Saerbeck, Germany) announced that it has acquired full shares in TK Industries GmbH (Selbitz, Germany), a medium-sized manufacturer of heavy-tow, multiaxial carbon fiber fabrics.
According to SAERTEX, TK Industries’ manufacturing technology is optimized for the use of cost-efficient 24K and 50K rovings, which complements SAERTEX’s current range of multiaxial fabrics. Applicable markets include the industrial and transport sectors, boatbuilding, marine, wind energy and infrastructure. SAERTEX plans to use common resources in purchasing, production and distribution.
“The acquisition of TK Industries will provide us with additional capacity in the short term to meet the ever-increasing demand for carbon fiber fabrics and thus enable improved delivery times for our customers,” says Christoph Geyer, CEO of SAERTEX Group.
“We have seen initial successes and are confident that, through the close collaboration, we will further enhance our range of multiaxial carbon fabrics. Our strength lies in spreading heavy tows at low areal weights and processing them into lightweight NCFs [non-crimp fabrics],” says Mirko Ackermann, operations manager at TK Industries.
Source | Composites World
Twenty-three presenters, including several European-based advanced manufacturing experts will address the impact of the Fourth Industrial Revolution on South Africa’s manufacturing sectors at the African Advanced Manufacturing and Composites Show on November 27 and 28.
The international line-up includes Grafton LSR Ltd Engineering Director Mark Chapman whose team has engineered the Bloodhound – the most advanced straight-line racing car ever built – to attempt to set a new world land speed record currently at 1227.985km/h.
Germany’s Frank Henning of Frauenhofer, regarded as one of the world’s foremost light-weighting authorities and Kjelt van Rijswijk CEO of Netherlands company SAM|XL housed at Technical University Delft and JEC World International Sales Director Yohann Cailleau based in France, also add an international perspective to the event.
Six workshops over two days will address the impact of 4iR on the automotive, maritime and general manufacturing sectors and focus on the rise and applicability of composites and advanced materials and manufacturing technology and process.
Other confirmed speakers include Retail Motor Industry COO, Jan Schoeman, Progressus platform manager Dr Harry Teiffel, South Africa Fraunhofer senior advisor Oliver Damm and former Director of the Centre for Polymer Technology Bernard Reeksting.
Co-ordinator Andy Radford of the Mandela Bay Composites Cluster said the speaker line-up is likely to also include Toyota MD Andrew Kirby, the CSIR’s Director for Advanced Manufacturing Martin Sanne, Jendamark CEO, Quinton Uren and Dr Anton du Plessis of the University of Stellenbosch, among others.
The Show, which includes an exhibition, factory tour and Gala Advanced Manufacturing Innovation Awards and Banquet will take place at the iconic Nelson Mandela Bay Stadium in Port Elizabeth with the support of the DTI and Mandela Bay Development Agency.
The Show, according to Radford, represents the largest gathering of Fourth Industrial Revolution roleplayers in Southern Africa.
It injected cash flows of R42,8m into the city’s business community in its inaugural edition, with Nelson Mandela Bay retaining host status for the second edition on November 27 and 28 this year.
The Show is hosted under the auspices of the DTI-supported, national Composites Cluster, in collaboration with government industry and academia.
Radford said the participation of over 3000 influential roleplayers positioned the inaugural Show as “Africa’s premier Initiative in the field supporting the triple helix model of innovation which involves interaction between academia, industry and governments, to foster economic and social development.”
Radford said plans announced by the AIDC EC to establish a globally inter-connected Smart Industrial Academy in the province, “attached to the prowess of global 4IR companies like Jendamark” positioned the Eastern Cape as a suitable host for the 2019 edition.
“The Advanced Manufacturing sector is highly fragmented in South Africa. Many associations and industry bodies promote advanced manufacturing but generally there is a lack of integration and awareness of even our own capabilities, which are substantial,” Radford said.
“Over 100 exhibitors showcasing three-dimensional printing, lasers, automation, virtual and augmented reality, artificial intelligence, drones and materials of the future are exciting tools to encourage a new generation of engineers and scientists but we need to expose them and industry to these technologies and there is no time to waste, ” Radford said.
The Show includes the exhibition, workshops, tech demos, factory tour, a drone demonstration and the National Advanced Manufacturing Innovation Awards.
For more information visit www.africanadvancedmanufacturingshow.co.za
Managing Director – Mandela Bay Composites Cluster
041 502 3713 or 072 375 3671