The ProblemThe Problem

Hardcore Composites currently uses a VARTM process to create bridges, marine applications, and custom molding.

part

vacuum

vac-pot

Mission:

The goal of our project is to design and implement a low cost vacuum-assisted resin transfer molding (VARTM) process that allows resin to recirculate through a lay-up. This process must also improve cost efficiency as well as time, labor, and material efficiencies.

Customers & WantsCustomers & Wants

Customers:• Scott Hemphill (President)• Jeff Pote (Process Engineer)• George Green (Production Supervisor)• Steve Schaeffer (Technician)

Wants:• Time Efficient (19.1%)• Material Efficient (17.5%)• Cost Efficient (16.7%)• Labor Efficient (16.1%)• Ease of Operation (11.6%)• Ease of Set-up (9.5%)• Ease of Repair (9.5%)

ConstraintsConstraints

Disposability: Anything resin touches must be disposable

No spark/flame: Styrene flammable, no sparks or flames formed during process

Continuous flow: Resin must continually flow through lay-up

Compatibility: Sub-process must smoothly attach and function with overall process

Reliability: Must meet (or exceed) present process’s reliability

MetricsMetrics

Metrics Target ValuesSpan time (13.8%) 1 to 24 hours

Project cost (13.2%) $2000 to $5000

Labor time (12.7%) 1 to 10 hours

Maintenance time (8.6%) 5 days/year

Setup time (8.1%) 10 minutes to 3 hours

Fill speed (7.9%) ~ 3.7 gpm

Drain speed (7.9%) ~ 5.0 gpm

System cost (7.1%) ~ $1100

Teardown time (6.1%) 5 minutes to 1.5 hours

Tank volume (4.5%) 10 gallons

Vent pressure [+] (4.3%) 3 to 6 psi

Molding time (3.4%) variable

Vacuum pressure [--] (2.5%) ~ 28 in Hg

BenchmarkingBenchmarking

Current technology: No VARTM recycling exists!

Competitors:

• Palmer Manufacturing & Supply

• Center for Composite Materials

• Advanced Process Technology

Companies that sell liquid transfer process components

Companies that use or sell VARTM processes for comparable products

Concept TreeConcept Tree

2-chamber

1-chamber

load - lock

pots

sensors/monitoring

gas delivery

valves

tubing

connections

check manual relief

weight float switch auto

flow meters regulators

seals lining protection brackets

Conceptsvacuum

vent vent

part

part

vacuum 28”

vacuum<28”

vent

Chosen Concept

TestingTesting

Feasibility Model

Check Valves

Sensors

PrototypePrototype

ScheduleSchedule