CANADIAN COMPOSITES SECTOR

TECHNOLOGY COLLABORATION,

INVESTMENT AND TRADE

OPPORTUNITIES

• Purpose: to describe Canada’s diverse composites industry in

terms of applications, technology thrusts and collaboration

opportunities to stimulate interest in investment and trade

• Sectors:

• Aerospace

• Automotive

• Ground Transportation

• Cross Sector Technologies

INTRODUCTION

Aerospace

EADS Composites

Atlantic

Bombardier Aerospace

Bell Helicopter Textron Canada

Avcorp Industries

Convergent Manufacturing Technologies

Comtek Advanced Structures

Magellan Aerospace

Viking Air

Boeing Canada Winnipeg

Inversa Systems

Pratt & Whitney Canada

Delastek

Avior

PCM Moulds

Cormer Aerospace

EMTEQ

COMPOSITE CAPABILITIES

Composite Fabricators

Original Equipment Manufacturers (OEMs)

Consultancy, Service Providers

NRC - AERO

NRC-AMTC

CCMRD

CIC

CRN

TECHNOLOGY CENTRES

Apex Composites

Aerospace

ORIGINAL EQUIPMENT MANUFACTURERS

Bell 407 Helicopter

Viking Twin Otter

Bombardier C-Series and Learjet 85 Pratt & Whitney

Canada

Aerospace

787 Vertical

Fin Fairing

787 APS/APU

Doors Engine Strut Aft

Fairing 737, 747,

767, 777, 787

Engine Strut Fwd

Fairing 737, 777 Wing to Body Fairing

737, 747, 787

Nose Gear Door

737, 767

Main Landing Gear

Doors 777, 787

Misc Ducts

747, 767, 777, 787

Composites Atlantic EADS Sogerma

EMTEQ Boeing Canada Winnipeg

Comtek Advanced Structures

COMPOSITE FABRICATORS

• Technology thrusts driven from national and regional

road mapping exercises

• Focus areas are:

• Out of autoclave processing

• Liquid composite moulding

• High temperature composites – ceramics, BMI, PI

• Automation: lamination

• Drilling and assembly

• Integrated structures including bonding and co-curing

• 3-D fibre preforms

• Thermoplastics

• Tooling

• Design for manufacturing

• Simulation and modelling * Manitoba priorities

TECHNOLOGY FOCUS

Aerospace

• Recent efforts focused on combining interests / developments into an integrated system of programs minimizing duplication

• Technology Readiness Levels (TRL) used to discriminate between each program type

• Programs are defined with a cohesive private / public funding strategy

• Linkages established to ensure that the appropriate industry, research organizations and academia are effectively connected and working at suitable TRLs

Aerospace

COLLABORATION

TRL

-10 +5

Program Launch

0 -5

Entry into

Service

Fundamental

Research

NSERC

CRIAQ

1

2

3

4

5

6

7

8

9

CIRAC

CRN

CCMRD

GARDN

TDP

SDTC

NRC

CIC

SADI

Product Development,

Manufacturing, In-

Service, End of Life

Aerospace

COLLABORATION

• National Sciences and Engineering Research Council of

Canada (NSERC) – TRL 1-3:

• Several programs that provide funding to university faculty/

students for research projects many with an industry focus

• Consortium for Research and Innovation in Aerospace in

Quebec (CRIAQ) – TRL 1-3:

• A non-profit consortium, established in 2003, to promote and

perform collaborative pre-competitive industry research

projects (TRL 1-3) primarily at Quebec universities

• Objectives - to increase competitiveness of the aerospace

industry, and enhance the collective knowledge base

through improved education and training of students

COLLABORATION

Aerospace

• The Consortium for Aerospace Research and Innovation in

Canada (CIRAC) – TRL 4-5

• Newly formed national entity: provides 50% project funding ($4

million per annum) for technology demonstration projects

• Projects require at least 2 companies and 2 research centres /

academia

• CRIAQ integrated within CIRAC

• To be the focal for the Canadian Networking Aeronautics

Project for Europe (CANNAPE)

• Formal arrangement between Europe (Horizon 2020) and Industry

Canada

• Open to industry and universities

• Coordinated call for projects opens in July 2014

• Project commencement and funding for April 2015

Aerospace

COLLABORATION

RESEARCH Activity

• Developing understanding

of the fundamental issues

• Creating the science

necessary to underpin the

development of KPDs

ENGINEERING Activity

• Integrating knowledge of the

fundamental issues with the

needs of industry

• Capturing the process in

KNOWLEDGE in PRACTICES

DOCUMENTS - KPD

INDUSTRY KPD Applications

• Product development

• Product improvements

• Training

• Defining Best Practices

• Decision Making

COLLABORATION

Aerospace

Coordinated by the

University of British

Columbia – TRL 4-7

• Canadian Composites Manufacturing Research and

Development Inc. – TRL 3-7

Aerospace

COLLABORATION

• CCMRD commenced in 2010 to conduct pre-competitive

collaborative projects to develop and enable commercialization

of composite materials and manufacturing technologies

• Produce a strong, integrated research and development

network and industrial supply chain

• Develop robust linkages between Canadian and

international partners, attracting global opportunities

• Projects jointly funded by industry and government

• Current projects include: Co-Processing, Out Of Autoclave Pre-

Preg, High Temperature Materials, Next Generation

Composites Factory Sensors, Dimensional Control

Members

Partners

COLLABORATION

Aerospace

• Green Aviation Research and Development Network

(GARDN) – TRL 3-7

• Funds industry led aerospace technology projects for the

protection of the environment – reduce aircraft noise and

emissions and greenhouse gases

• Technology Demonstration Program (TDP) – TRL 6 max

• Recently introduced program that supports large

aerospace technology demonstration programs - $55

million allocated annually – 50% project contribution

• Focus is to move new technologies out of the laboratory to

test them in real-world settings

• Encourages supply chain development across Canada

• Can include international partners who bring unique

capabilities to a project

Aerospace

COLLABORATION

• National Research Council Canada: Aerospace – TRL 3-7

• Recently reorganized into several program areas

• Has large scale composites manufacturing facilities and materials

and structures inspection and testing capabilities

• Participate in industry led projects providing technical services

• Has project sponsored by EADS

Aerospace

COLLABORATION Advanced Fibre Placement:

Forward Fuselage

RTM Rib for Helicopter Wing

Box

Radial Adhesive Joining of Barrel

Sections

• Composites Innovation Centre (CIC) – TRL 1-9:

• Winnipeg has a diverse manufacturing industry due to its

unique blend of Original Equipment Manufacturers, Tier 1

suppliers and secondary suppliers

• Composites has become a key economic driver:

• Boeing Winnipeg – largest aerospace manufacturer of composites

in Canada – 1600 employees

• Magellan Aerospace – 130,000 sq.ft. recent addition to meet F-35

production requirements (BAE Systems)

Aerospace

COLLABORATION

• Composites Innovation Centre (CIC) :

• Mission: To drive economic growth in the composite

manufacturing industry through:

• Assisting industry in developing and commercializing current and

new composite applications and technologies

• Being the catalyst for attracting new industry and encouraging

start up companies

• Achievements:

• Over 10 years launched 361 projects with industry partners,

transferred 87 technologies to industry and established 26 new

capabilities with clients

• Recognized for composite design/analysis and as an international

leader in biomaterials development and commercialization

Aerospace

COLLABORATION

Industry Led - Partner Supported

CIC BOARD OF DIRECTORS

• 30 permanent staff, 8 students

• 28,000 sq.ft. of office and laboratory

• Engineering Services

• Design (CAD)

• Finite element analysis (FEA)

• Process development

• Prototyping

• Manufacturing problem solving

• Specimen preparation and testing

• Project management

• Business planning

COLLABORATION

Composites Innovation Centre

• National / International Partners

China Projects:

Tianjin

Polytechnique,

Shanghai Light

Source

Biocomposites

International Research

Network Member

University of British

Columbia:

Composites

Research Network

NRC Biocomposites

Flagship and

Aerospace Programs

European Collaboration

Biomaterials –

Normandy

CRC-ACS

Composite Centre –

Melbourne $65

million project University of

Alabama, Student

Sponsorship

Composites

Innovation Centre

North American

Industrial

Bioproducts

Consortium

Legend:

Current Partnerships

New Opportunities

Composites Innovation Centre

COLLABORATION

• Composites Innovation Centre (CIC) –

TRL 6-9

• JSF Qualification & Continuous

Improvement Production Support

• 787 & Derivative Design, Prototyping

and Process Development: Main

Landing Gear Door, Shear Ties, Ducts

• New Product Development and

Alternative Materials Evaluation

• Establishment of “Green-Field”

Composite Fabrication Cells

• Composite Structural Design, Analysis

and Technology Development: On-site

Support

Aerospace

COLLABORATION

Automotive

TECHNOLOGY FOCUS

• Canada has a very well connected supply chain with

several Original Equipment Manufacturers (OEMs), Tier

1 Suppliers and Research and Test Centres

• Main interest in reducing weight while maintaining

performance and cost: new designs; carbon, agricultural

and wood based fibres; fast cure resins

Magna International

All-Thermoplastic, Composite,

Fully Recyclable Liftgate Module

for the 2014 Nissan Rogue

Composites Innovation Centre

Natural Fibre Reinforced

Demonstration Electric Vehicle

Automotive

• R&D Infrastructure is mainly clustered in Southern Ontario

• OEM R&D and Test Centres – many related to cold

weather testing – extreme in Manitoba!

• AUTO21:

• National network of centre of excellence for automotive R&D

that partners 200 researchers from 46 universities with private

companies

• Some university partners:

• MacAUTO – McMaster Institute for Automotive Research and

Technology

• WarCar – University of Waterloo Centre for Automotive Research

• UOIT-ACE – Automotive Centre of Excellence / University of

Ontario Institute of Technology

• University of Windsor

COLLABORATION

Automotive

• Recently established 2 composites centres focused on

next generation of medium to high volume production

processes, shorter cycle times, increased automation

and improved quality control

• Fraunhofer Project Centre @ Western

• Centre houses advanced manufacturing equipment for

producing industrial scale lightweight composite parts

COLLABORATION

Compression Moulding

Direct Sheet Moulding Compound (SMC) Line

Long-fibre Reinforced Thermoplastics (LFT-

D-ILC)

High Pressure Resin Transfer Moulding

(RTM)

Automotive

• Magna NRC Composites Centre of Excellence

• Composites manufacturing and light-weight structures and

technologies, including renewable resources and advanced

materials

• Funding programs through NRC-IRAP (Industrial Research

Assistance Program) and collaborative industry projects

COLLABORATION

Dieffenbacher Long Fibre Thermoplastic Line

Industrial Scale

Ground Transportation

• Canada has numerous ground vehicle manufacturers

that have significant composites content:

ORIGINAL EQUIPMENT MANUFACTURERS

Buhler Tractors Westward Industries

3 Wheel Vehicle

Triple E

Recreational Vehicles

New Flyer Industries

Transit Buses Motor Coach Industries, Prevost

Over the Road Coaches

Ground Transportation

TECHNOLOGY FOCUS

• Technology focus related to reduced vehicle weight and

cost, increased durability, improved performance and, in

part, recycling/ renewables

• Design approach focused on reducing part count

• Lower cost carbon fibre forms

• Renewable materials – natural fibres/resins

• Process automation; laminating, trimming

• Liquid resin moulding

• Compression / vacuum moulded panels – new substrates

• Lower cost tooling

Natural Fibre Reinforced Tractor Parts

Ground Transportation

COLLABORATION

• Several technology centres provide direct support to

industry:

• Composites Innovation Centre (CIC)

• Regional Industrial Technology Centres – Alberta Innovates,

Industrial Technology Centre Manitoba

• Development Centre of Quebec Composites (CDCQ)

• National Research Council Industrial Biomaterials Flagship

Program (NRC)

• Composites Research Network (CRN)

• University support is generally regional – resources

dependent upon local industry interests

Cross Sector Technologies

• Composite technologies of interest:

• Biocomposites

• Green building materials

• Carbon fibre applications in other sectors outside of

aerospace:

• Sources of low cost carbon fibre

• Composites recycling

TECHNOLOGY FOCUS Mechanical Recycling

Functional Lignin Based

Carbon Nanofibres

Hemp Reinforced

Concrete Blocks

1

2

1 ECO-WOLF Inc.

2 University of British Columbia

Producers Decorticators

Test

Facilities

Mat

Producers

Composite

Part

Fabricators OEMs

Material

Distributors

Resin

Developers/

Suppliers Strategic Plan:

• Product Demonstrators

• Technology Development

• Supply Chain Gaps

• Biomaterials

• Objective: To develop the rural economy through sustainable

commercialization of available biomass

Cross Sector Technologies

COLLABORATION

Snow Board

Product Demonstrators

Ecocycle Fuel Tank

and Fender Panel

Bus Door,

Sidewall and

Floor Panels

Gazebo Roof

Mid Range Speaker

Tractor Hood & Fenders

ACCOMPLISHMENTS

Electric Vehicle Body

Green Building

Material Applications

in New Facility

Green Garage at

the University of

Manitoba (MAFRI)

ACCOMPLISHMENTS

Product Demonstrators

INNOVATIONS

• To create a global centre of excellence for fibre grading

to rapidly assess the quality of natural fibres and provide

the necessary confidence that the materials will meet

industry standards

Natural Fibre Structure X-Ray Diffraction to

Measure Microfibril Angle

Confocal Microscopy for

Microstructural Analysis

FIBRE CITY

GOVERNMENT

Genetics

Working with

breeders to

design and

deliver the

optimal fibre

resource.

End Markets

Championing

the use of

biofibre

products in

the market

• Optimal

GxExT

combination

• Systems

biology

Fibre Supply

Supporting

Farmers and

Decorticators

to produce the

highest value

products

• Fibre testing

• Managing

variability

• Regular

feedback from

higher value

chain

participants

Standardizing

Leading

industry and

academic

efforts to

standardize

quality

assessments

• Int’l Standards

Organizations

• Drafting new

standards

• Standard

Operating

Procedures

Material

Production

Working with

component

industries to

improve their

supply and their

end product

• Product testing

• Fibre input

testing

• Regular

feedback from

higher value

chain

participants

Fabricating

Assisting

industries

new to

biofibres to

achieve

desirable

results

• Design

guidelines

• Technology

transfer

• Prototyping

• Promoting

whole industry

• Identifying new

markets

COLLABORATION

• Biocomposites improvements: topochemistry analysis of flax fibre

bundles encapsulated by resin – FT-IR Scan

Penetration of Resin

into Fibre Bundle

Electron Microscopy of

Fibre Bundle

FT-IR Scan of Fibre

Bundle – illustrates

bonding regions

BIOMATERIALS

Biocomposites

Cross Sector Technologies

• Biomaterials:

• Commercialization of biomaterials has regional and

national networks

• National support through Agriculture and Agri-Food

Canada – several programs

• Regional support – Manitoba Bioproducts Strategy

• International activities – pre-competitive collaborative

research

• Active pursuit of international investment in

technologies and production capabilities to build the

supply chain

COLLABORATION

1

1 SWM International

Cross Sector Technologies

• Low cost carbon fibres:

• University of British Columbia has developed lignin based

carbon nanofibres using residuals from Canada’s forestry

industry

• Initial commercialization focus leveraging superior

electrical and thermal conductivity properties:

• Surfacing films for EMI shielding of aerospace panels

• Automotive gaskets for EMI isolation and protection of

electronic devices

• Electrodes for fuel cells and batteries for enhanced electrical

conductivity

• Coatings for construction applications to provide a radiated

heat source and EMI shielding

• Efforts to attract investment in Canadian based pilot/

commercial scale nanofibre production line

COLLABORATION

Cross Sector Technologies

• Composites recycling:

• Focus on utilizing mechanical processing to produce

recyclate for concrete reinforcement to minimize matrix

cracking

• Supply chain development based on consumer pull and

involvement of existing waste management infrastructure

COLLABORATION

Fibreglass Recyclate Used in Concrete Slab

• Interest in pyrolysis recycling through international

partnerships: ITRB Consulting

• Canada has a significant composites industry feeding

regional, national and international markets

• Sectors generally have a well defined technology focus

• Companies, funding agencies and research organizations

eagerly engage to advance technologies and supply

chains

• International collaboration and investment is recognized

as a key enabler in building and advancing the industry

• Many opportunities exist for international partnerships for

mutual commercial and technological benefit

SUMMARY

CONTACT INFORMATION

Sean McKay

President and CEO

www.compositesinnovation.ca

204-262-3400 ext. 202

smckay@compositesinnovation.ca