i-Composites brings processing capability forward

The i-Composites Grand Challenge, led by GKN Aerospace and coordinated by the National Composites Centre (NCC), has been a focused programme looking at advancing composite production expertise and capability. The programme features a consortium of 23 companies and £10m of funding coming from the Department for Business, Innovation & Skills (BIS) and member companies across a whole portfolio of projects, and has been run by the Technology Strategy Board (TSB).

The programme is essentially the other key initiative of the UK Composites Strategy along with the NCC and has been concentrated on improving affordability through the rapid manufacture of composites and making this technology accessible to the UK supply chain.

Of the total 26 projects running under the i-Composites banner, there have been four key themes identified and addressed and looking at both non-recurring and recurring aspects of the value chain: the key blockers of process time reduction, developing better automation, and bringing forward capabilities in both materials and simulation. The spread of industry sectors encompasses the major composite users of automotive, aerospace and wind and involves a range of business models which require different answers to different problems. There has been a high degree of technical integration between projects. An example of this within the energy reduction theme involves Airbus, Fraser Nash, and Aircelle. This theme started off with four distinct projects which, through extensive cooperation throughout the year, have effectively coalesced into one.

Progress was always going to be difficult but the results are encouraging. Particular technical successes have been achieved in the areas of automation and in material development. A team led by Bombardier Aerospace, Belfast for example has developed an array of grippers to handle dry fibre preforms. Sigmatex has also developed a technique for weaving 3D multiple stiffening element sections simultaneously.

The breakneck speed of the Grand Challenge has required some deft project management, so GKN brought in Axillium Consulting to accomplish the project management function. Will Searle, director of Axillium and programme manager for i-Composites explains: “The main thrust of project management was to keep it focused and light. We compressed a three year programme into 12 months, with the emphasis on technology.” With 22 partners and 26 projects it needs this light touch and it was important to have collaboration agreements set up from the word go, an open project management structure, and monthly steering group meetings instead of the usual quarterly cycle. Within these meetings, workshops were held to address particular issues and foster collaboration across sectors.”

The planned deliverables are still on target for the end of March. The demanding timescale has concentrated effort on resolving issues and this has provided a lot of organisational character building. The programme has established new collaborations between partners and cemented new relationships as partners have worked together to resolve problems.

The working relationship with the Government funding bodies TSB and BIS has been key to successful completion of the project. The TSB Monitoring Officer has thoroughly scrutinised progress at every stage and helped to resolve some of the technical programme problems encountered.

The outcomes of the Grand Challenge are going to feed into the other cornerstone of the UK Composites Strategy, the NCC. i-Composites programme leader GKN is one of the founding partners of the NCC and has made sure that unresolved issues which have been encountered during the Grand Challenge will be considered for the NCC core research programme.

Finally, there has been a strong focus on dissemination. As well as the impact on core partners, the project will have a direct impact on over 60 suppliers beyond the partnership. i-Composites provided the main stand at Innovate 2010 and the project website has a wide range of information about applications. Most importantly however, UK industry is now hearing about composites through the outputs of the Grand Challenge.

www.i-composites.org