The only thing surprising in the Dreamliner delay announced yesterday is that anyone is surprised. As reported here in an award-winning online package, this project is one of the most demanding ever taken in terms of technology and supply chain. The first flight will be delayed six or so months? The Airbus A380 is delayed two years, and it wasn’t a major leap forward. Everything about the Dreamliner is daunting, particularly the brave jump into full-boded composites technology, a move that Boeing bet the whole ranch on. Boeing is sole sourced on the carbon fiber and prepregs that make up the composites. Toray had a fiber capacity of 7,300 metric tons in 2003 and 13,900 metrics tons earlier this year. Huge expansions continue, and Toray’s capacity will approach, if not exceed 20,000 metric tons by 2010, based on Design News estimates. Even more daunting is the effort to automate, and dramatically speed up composite manufacturing processes. As Boeing composites guru Al Miller told me earlier this year: “The technology area still playing out is tooling. Left to its own devices, composite tooling can be fairly elegant or—if you’re not paying attention to it—it can be very clumsy and heavy…We had to meet with our technology partners up front to make sure the technology was mature enough to meet our production schedules.” The builders of the giant tools to make the composite structures are virtually a cottage industry —and one that did not even exist two years ago. The examples go on and on. And what’s more, Boeing, like many other leading edge OEM’s has pushed a huge amount of the development out to its supplier partners. That’s smart, but also risky. I for one applaud Boeing for its efforts, and hope the TV news readers and other headline-focused media don’t shake this tree too hard. In many ways this may be the future of American product development.
At the JEC Europe 2015 composites show in Paris last month, makers of composite materials, software, and process equipment showed off their latest innovations. This year's show saw some announcements related to automotive applications, but many of the improvements came in the world of aerospace.
The DuPont-sponsored Plastics Industry Trends survey shows engineers want improved performance in a broad range of plastics and better recycling technology. These concerns top even processing enhancements that improve productivity.
Plastics leader SABIC recently announced a global initiative to help its customers take advantage of additive manufacturing (AM) and also advance 3D printing (3DP) technologies in several application areas. The company's plans go way beyond materials, and also include design, processing, and part performance.
A theme that was reflected in several ways at NPE 2015 was the use of 3D printing to assist in, or improve on, injection molding, as well as improvements in 3D printing materials and processes that are making better functional prototypes and end-use parts.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.