In his session We’ve Got to START Meeting Like This, Douglas Caudle, president of Piedmont Fiberglass, emphasized the importance of bi-monthly and monthly meetings. “When you have those meetings, be honest with your employees,” he says. It is important to share the vision with them so they feel engaged and can help you meet company goals. “Folks have anxiety, tell them the straight truth, after all, knowledge is power,” he said.

Caudle also emphasized certain etiquettes that should be followed at every meeting. Whether it’s a one-on-one, a department meeting or an all-staff meeting, there are certain things you should and shouldn’t do. While the list of “good things” can become very long, there are basic no-no’s everyone should follow:

1. No phones.  Turn off all cell phones and let staff phones go to voicemail, which is why it was invented.
2. No laptops. If you allow laptops, nine times out of ten the owner won’t be taking notes, they will be surfing the internet. Keep everyone engaged and have as little electronics as possible.
3. No eating. Each person may think they have the best manners in the world. But, to the person next to you, you could sound like a cow chewing on its cud. “When you eat, you distract others from the discussion, at that point the meeting is tallied at a loss,” said Caudle.
4. Stop side conversations. According to Caudle, the second most distracting thing besides eating is a side conversation. He suggested the most effective way of stopping the side conversation: stop your own conversation.

Dave Warren, field technical manager at Oak Ridge National Laboratory, is heavily involved in carbon fiber research. He shared his expertise as well as the state of the material in the marketplace during a Friday afternoon session titled Applications for Lower Cost Carbon Fiber.

According to Warren, while fuel economy has remained largely the same in the past few decades, vehicle weight has gone up. Recent developments (such as the energy crisis) may buck this trend, resulting in a desire to reduce mass, which carbon fiber is ideal for. As it stands now, despite having been included in vehicles since the 1970s, only about 1 to 2 percent of vehicles are made with carbon fiber material. In fact, market penetration in general was miniscule, but a breakthrough came in 2005 when companies like Boeing and Airbus made significant investments in carbon fiber for their products. Since then, production has increased tenfold.

But the material is still not ubiquitous in manufacturing due to its high cost and lower level of demand. Nevertheless, Warren says there are many markets in which carbon fiber has the potential to expand, including wind energy (longer blades can capture greater energy) and power transmission (replacing steel with 66 percent less mass). Currently, Warren continues his research on behalf of the U.S. Department of Energy’s Energy Efficiency and Renewable Energy division.

Tom Wood, principal of Stoel Rives LLP, Oregon, is an attorney who practices environmental law. He updated attendees on looming regulatory possibilities for greenhouse gas emissions (GHGs). He emphasized that regulation is inevitable and what manufacturers have to wonder is exactly how much costs will rise as a result. Companies that manufacture products directly and emit greenhouse gases will be most affected by cost increases, but energy prices will increase, which will affect all companies indirectly.

Wood listed GHGs that are or will be most likely regulated, including CO2, methane, nitrous oxide, hydrofluorocarbons, perfluorocarbons and sulfur hexafluoride. Currently, a number of outside parties have created protocols that outline methdologies used for calculating emissions. Thirty-nine states have already agreed to submit data they collect to one of those parties, The Climate Registry.

As the pressure to reduce emissions increases, cap and trade programs are likely to become more prevalent. Generally speaking, regulatory agencies implement cap and trades by limiting the total amount of emissions allowed among a given set of companies. "If you've ever played musical chairs, you know everything about cap and trade programs," Wood said.

Robert Noble, founder of Envision Solar, came to COMPOSITES+POLYCON searching for the composites industry’s help. As architect and engineer of Compositrees’, his company is looking for ways to cut down time and cost to his booming product. A Compositree product incorporates solar panels, parking solutions and sleek architecture into one.  “I came all the way here from San Diego because I thought composites could help,” Noble began. “One large problem, however, is the lack of specialized knowledge needed to incorporate composites into the structures.” We soon discovered it was the same in reverse. When Noble asked session attendees to raise their hands if they were familiar with solar panels, no one raised their hand. Throughout his 45 minute presentation Noble outlined projects his company is working on and their various applications, ranging from parking structures in malls, medical centers, a university campus and individual companies. He presented photos of his product and highlighted areas (such as framing) he hoped to replace current products. “This is a glimpse of the future,” he concluded. “Solar panels, ports for hybrid vehicles and local architecture.” The only question remains, will composites manufacturers be a part of that future? Envision Solar hopes so. For more information on solar panels or Compositrees, click here.

If you walked in late to this session, you may have thought you were walking into a Taekwondo class instead of a composites forum. Standing at the front was a gentleman demonstrating the ease of breaking a wooden panel, yet when it came to the FRP wood panel he had a little trouble. Larry Parent, senior R&D program manager for the University of Maine-Advanced Structures Composites Center (AEWC), presented the school’s research findings on blast-resistant wood. The panels, for the U.S. military, were designed to be lighter and stronger than normal wood paneling.  Results showed that the reinforced wood absorbed six to seven times more energy. Attendee Ervin Geiger, engineer manager for Advanced Processes Technologies, said “I came to this session because it is something unique. The most impressive thing to me is how much composites add to the strength of the wood.” AEWC began research for the U.S. military and would like to extend its application to public and private buildings to aid in natural disaster. 

Visit the MVP Booth #811 on Friday to see the following processing demos:

10:30 a.m.
Light RTM

2:30 p.m.
VIP

4:30 p.m.
CCBM

Former ACMA president Bill Kreysler presented a session Thursday afternoon titled Composites in Construction with a Vision of the Future Today–Case History on All Composites Residential Structure. Though the title of the presentation was lengthy, the premise was quite simple: Composites can lend more to construction than many people think.

Kreysler explained the reasons why composites are not seen as a viable alternative in the construction market. Much of it had to do with the fact that the concept prevails against common wisdom: Composites are too conservative and traditional materials are too enmeshed into the culture as it is. He argued that countless advances have been made with the development of materials such as reinforced concrete. The main issue, he said, is recognizing that manufacturers need to spark innovation.

The focal point of the presentation was a residence in San Francisco. A local woman hired Kreysler’s company to build a house made entirely of composite materials. The company immediately went to work on creating the unique structure from FRP panels. The company faced some challenges, having to transport the house in six parts and needing to add stucco to the roof for the house to meet California fire standards. The house was small, only about 40 square feet, and bore a shape resembling a beehive. Nevertheless, Kreysler points to the finished product as a harbinger of things to come and as proof that utilizing composite materials in this way is a legitimate course of action.

COMPOSITES+POLYCON attendees networked during a welcoming reception on Thursday night.

An employee steps out to get lunch for the company and gets into a car accident. Would you believe that his employer is liable? With the country enduring a trigger-happy approach to lawsuits, scenarios such as this one can have devastating effects, including a damaged reputation and loss of assets, G. Kent Mangelson, CFP of the American Society for Asset Protection, shared some protection strategies during an education session yesterday morning.

 The presentation focused primarily on limited partnerships, which allow individuals to protect personal finances (CDs, savings), real estate and homes. The key to protection is to avoid mixing safe assets (the money) with the high liability assets (properties), Mangelson said. The latter trigger lawsuits, and mixing the two strip your protection on those high liability assets.

Magnelson also discussed a concept called a charging order. This was described as the only course of action a judge would ever sentence when he sees a person’s assets were properly distributed. It is seen as not a viable option for the person filing the lawsuit because they cannot get any percentage of an individual’s assets or income. It is only seen as an option to go after an insurance company.

For more information on Magnelson and his association, visit www.americansocietyap.org

"We stand here today in the 13th consecutive month of recession," said Dr. Richard Tutterow of Mercer University, Macon, Ga. He addressed nearly 200 attendees during the ACMA General Session about the state of the economy and its future prospects.

Tutterow pointed out that the average for post-WWII recessions is 10 months, so "this recession is already a little long in the tooth." High energy prices, a credit crunch and a sharp correction in the housing market are factors that contributed to current economic environment. Nonetheless, the economy isn't as damaged as some people say: "Anyone that tells you what we're working through right now is comparable to the Great Depression is greatly overstating their case," Tutterow said.

Sealant Equipment and Engineering made a return visit to C+P after several years away. The reason, said Vice President of Global Sales and Marketing Ken Jacobs, was to reinforce networking resources as the company shifts its focus to different markets.

Jacobs, a longtime veteran in liquid control, recently appointed to the position, said that less attention will be paid to the automotive market. With declining production in that sector, Jacobs feels the time is right to put more resources into such emerging markets as wind and solar energy. He notes that these alternative markets are not only receiving the attention of manufacturers, but of the government as well. “The money is going to be put in for development,” he says.

For more information, visit Sealant in booth #1824.

Tom Pinske, president of Plato, Minn.-based The Pinske Edge, offered attendees tips on improving their production workflow during an educational session titled Shop Process Optimization.

Among his suggestions, Pinske told attendees to store common materials in the same location, so they’re easily located. He did this in his own shop after realizing that the adhesives were scattered throughout the workspace.

Pinske described the production process as a “pulling through instead of pushing through.” He suggested that companies determine the number of hours needed to do a project and change their production schedule so that jobs are started that many hours before the deadline. “When you get an order, the first thing to ask is ‘when is it due?’” he says. “There’s no point in cutting your sheets right away.” Otherwise, the project sits in your shipping dock long before they go out.

According to one study, we’ll need two Earths to sustain the world’s population at the current rate of consumption by the year 2050, says Dr. Michael Lepech, assistant professor at Stanford University’s Department of Civil and Environmental Engineering: “Obviously, that’s not going to happen. So creating a more sustainable or ‘green’ life is the way to go.”

Lepech presented a session at C+P this mornign called Life Cycle Assessment Methods for Design and Manufacturing of Sustainable Composites. However, going green can be a precarious route. “It will do your company no favors if you say you are green, and then a watchdog group or a competitor discovers you aren’t,”  Lepech says.  To avoid this, he outlines what he called the IPAT, which stands for the following:

Impact = (Population size) x (Affluence) x (Environmental Damage)

Evaluating these variables allows companies to know what changes need to be made within their practices and products. Does a policy change need to occur, such as a tax cut or increase, public service announcement or lobbying? Or is a technical or process change needed in your plant? Lepech suggested that with three labels, a composites manufacturer can hopefully avoid greenwashing.

Type I, a third party assessment such as LEED.
Type II, a label developed by the products producer, focusing on a single attribute.
Type III, an eco-label awarded to a product based on a full life cycle assessment (such as a “made out of recycled material”.)

For more information on life cycle assessment click here.

The ICPA General Session opened this morning with presentations from three suppliers who are featuring new products in their C+P booths.

Bill Jeffries, product leader of non-reinforced resins for AOC, touted the benefits of the company’s A830 series resins, which were developed to minimize resin usage. More information is available at Booth #900.

Renee Hall, marketing manager for The R.J. Marshall Company, talked about the company’s new granite fillers, which were influenced by the look of natural stone. More information is available at Booth #823.

Jack Simmons and Larry Brannan from ACS International also promoted their lines of granite effect fillers. More information is available in Booth #708.

Following the presentations, ICPA President Dirk De Vuyst updated the membership on the alliance’s recent activity, including changes to bylaws and the status of the MasterCast branding initiative.

In an educational session earlier this morning, Brock Strunk, engineer for Spirit Aerosytems, weighed the benefits of replacing or repairing parts on composite aircraft structures. The session, Integrated Composites Structures (ICS) Tooling for Commercial and Military Aircraft, focused on the need for each manufacturer to evaluate whether replacing or repairing a composite part is more beneficial. Strunk stressed that it’s important to create a plan because in today’s market there’s an increasing amount of product manufactured out of composites.

Strunk outlined several considerations each company must make when deciding to replace or repair composite parts. The first is cost. Is it more cost efficient to repair a damaged part or replace it?  Many equate repairing as the quicker and easier method, but that is not always the case.

Second, how much time can you afford to lose? Strunk advised that it is a fine balance between what saves time in the here and now, and what will be sustainable.

Third, Strunk told attendees to evaluate their manufacturing environment as well as the environment their product will be placed in. A composites piece placed outdoors will most often be subject to harsher elements than those that are indoors. 

Jack Simmons, ACMA Conference Commitee Chair, cuts the ribbon at the COMPOSITES+POLYCON exhibit hall, signifying its official opening.

ACMA hosted a reception where active members of the association gathered to network the night before the offical start of COMPOSITES+POLYCON. For more photos, click here.

Until recently, patent restrictions limited Rimtec from serving the North American market directly. Starting in 2009, Rimtec will serve the North American market through Zeon Chemicals, the U.S. subsidiary of Rimtec’s parent Zeon Corporation.

According to a press release, the companies will officially announce the partnership at the COMPOSITES+POLYCON. Their booth will feature Rimtec’s Telene DCPD resins, which allow a high level of freedom and efficiency for creating to small- to medium-sized series of large parts, including small-scale wind turbines.

A MyPower wind turbine will be on display at the ZEON/Rimtec booth No. 129.
 

It’s not as mysterious as you think: ““The real secret to closed molding is attention to detail. It’s excruciating, continuous and throughout the process,” says Mike Angerer, president of manufacturer New Boston RTM Inc. “Open molding is very commercially viable because it’s very flexible. It doesn’t take the same accuracy of materials or process, because you’re able to make changes on the fly and there are multiple steps involved where you can make adjustments. With closed molding, it’s a one-shot deal.” On the other hand, closed molding can yield more accurate parts and a cleaner work environment.

Angerer made the transition to closed molding over a period of many years. Fortunately, the learning curve isn’t as high as it used to be, he says. At COMPOSITES+POLYCON, he’ll lead an education session titled How Critical Is Process Control to RTM/ RTM Light? Designed for anyone interested in the process, the session will highlight common problems that manufacturers experience using closed molding, including poor part fill, poor surface quality and losing consistency of shape with molds. 
 
Angerer anticipates greater adoption of closed molding as a result of the economic downturn. “What’s happening is that everybody is looking for something different, so you’re getting industries and people looking at different materials,” he says. “Our industry is looking at anything else we can replace. The challenge is that most of those other materials have a higher degree of innate accuracy to them when you process them. When you stamp a piece of metal, the accuracy is great. When you cut a piece of wood, it’s pretty darn accurate. To get into these other industries, you’re going need a process that’s clean and accurate.”

This session takes place on Thursday, Jan. 15 from 2 p.m. to 2:50 p.m. For more information, click here.

Interest in closed molding processes continues to grow as economic and regulatory pressures affect the way composites products are manufactured. The need to produce quality parts, reduce material
waste and minimize emissions is driving the adoption of closed molding technology.

Manufacturers and fabricators can learn about closed molding through a series of educational videos offered by ACMA. Filmed live at ACMA’s Dynamics of Composites conference in Dayton, Ohio, the videos demonstrate how different closed molding techniques can increase efficiency and reduce
costs.

The following videos are available for the first time at COMPOSITES+POLYCON 2009:

• Resin Transfer Molding Controls Key to Bottom Line Controls
• Light Resin Transfer Molding in the 21st Century
• Advanced Techniques of Light Resin Transfer Molding
• How to Build a Closed-Cavity Bag Mold
• Advanced Techniques in Vacuum Infusion

To purchase the videos, visit the ACMA Booth or email Adam Seery at aseery@acmanet.org.