A new direction into design

Hampshire-based composites specialist, Combined Composite Technologies has opened a new manufacturing and research facility. Ed Hill discovers how the move coincides with a new direction for the company. The recent developments at Combined Composite Technologies (CCT) are the embodiment of the current trend of increasing expansion within the composites sector. The company, which can trace its roots back 50 years, moved to a new 44,000ft² composite design and manufacturing facility in Segensworth in October 2012.

The development is part of the company’s expanding role within its US parent group Momentive and signals a change at CCT from a well-respected build to print company to increasingly focusing on R&D.

General manager Paul Collier explains the company’s new strategy: “This is a major change in direction. We already have a strong customer base but we want them to look upon us as more than just a supplier of components and tooling. We want them to see we are a company who can help them with new products including design, testing, material development, process development and prototyping.”

Global partner

CCT is part of Momentive’s Speciality Chemicals division (formerly Hexion), whose history dates back to the invention of plastics such as Bakelite. The group had an annual turnover of US $7.8billion in 2011 and has more than 90 manufacturing facilities around the world.

Momentive’s investment in CCT demonstrates the enormous potential corporations anticipate in the composites sector. As a major supplier of thermoset resins and other raw materials it is keen to exploit new applications in composite manufacturing.

The resources at the new facility demonstrate the move to research and development. A new design area currently accommodates five CAD stations and the company is in partnership with Matchtech Engineering recruitment services to find design engineers who work on projects through systems such as Finite Element Analysis (FEA). The design area can accommodate up to ten staff if required.

Collier explains: “This means we can create new opportunities for ourselves because we have the capability for composite design as well as the manufacturing process. It means we can get involved in projects at the front end of the design and manufacture. For our design partners, it allows them to say they now have a manufacturing capability, so the partnership works both ways.”

The new facility also includes two clean rooms, one specifically to meet the demands of the International Traffic in Arms Regulations (ITAR) and the company has ISO 9001: AS9100 Rev C Certification. Three further materials laboratories are available to develop the next generation of composite resin systems and prepreg materials.

CCT’s main customer base is currently supplying composite tooling and components to OEMs and primes in the aerospace, defence and the high-end automotive sectors, but it also sees sizeable potential in the renewables sector.

“We want to incorporate renewables where Momentive Speciality Chemicals already has a great deal of experience,” comments Collier. “At CCT we are working on a number of projects within the renewable energy sector for the design and manufacture of composites structures and components that brings to bear Momentive Group’s knowledge and experience in this sector with resin systems and our own core capabilities within component manufacture.”

The company also hopes to be the main European manufacturer and distributer of a new material being developed by Momentive designed to improve thermal conductivity.

In addition to the enhanced design capabilities, the shopfloor houses new tooling and processing equipment. Around £300,000 has been spent on equipment including a 5-axis CNC machining centre for in-house master model creation capabilities as well as trimming, drilling and planing of composite and aluminium components, including carbon. “This is used for our own in-house processes so we can maintain control of the timeline for ourselves and our customers and rely less on subcontractors,” Collier states.

In at the beginning

The aim of the company is to concentrate on high-value product development rather than large scale manufacturing. Sales manager Rob Collinson highlights: “We intend to become a centre of knowledge for Momentive Global. Our focus is going to be on the design, prototype and test manufacture of small batches to then pass on to large volume production manufacturers or other elements of the group.”

Joseph Bevilaqua, president of the epoxy, phenolic and coatings division of Momentive Specialty Chemicals adds: “The combination of CCT’s solutions and our speciality portfolio will extend our capabilities and help us build partnerships with co-suppliers and customers, as this is key to the successful development of structural composite solutions for mass production in the automotive, aerospace and mass transportation segments.”

So 18 months into the new strategy how successful has it been for the company and its 45 employees? “Since we have moved to our new site we have invited representatives from the majority of our prime and tier 1 customers to take a look at what we have been doing.” Collinson reveals. They have seen the new facility and the new attitude behind the company and have been impressed.

“We have managed to retain the skill sets from our previous site at Chandlers Ford and the workforce can see the investment that is going into the company and its potential. In the next year or so we may also look at developing an apprentice scheme.”

The developments at CCT are already seeing results with enquiries on the increase and extension into other markets such as space technology. The company also unveiled its new branding at last year’s Composites Engineering Show.

“We took a conscious decision not to put any large composite structures on our stand because we wanted to promote conversation about the new company,” Collinson continues. “The whole organisation has changed to be more open and consultative. It means our research and technical skills will be utilised in products that can then be sold globally. This is something we would not have been able to do in the past without the support of the Momentive Group.

“We want to be the science behind making the virtual actual. Customers can come to us and we can assist with the design and make them aware of the materials that available and then prototype and test it. We aim to be a one-stop source, pushing the boundaries within the composites market.”

www.c-c-t.co.uk