Www.centurydesign.com On Demand Prepreg. Agenda History of Prepreg Prepreg markets today Prepreg...

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On Demand Prepreg


Agenda

• History of Prepreg

• Prepreg markets today

• Prepreg from a Suppliers perspective

• Prepreg from a User’s perspective

• Why “On Demand Prepreg” is now possible

• Key issues to consider

• Conclusion


History of Prepreg

History of Prepreg• First Prepreg machine developed in 1969 to support carbon tape for NASA lunar lander

• Resin systems were difficult to use, mix, catalyze, process consistently, control tack, etc.

• Prepreg processing machines employed by end users for their own materials

• Materials suppliers started providing prepregs (e.g. Narmco, Fiberite, Ciba)

• New resins, materials and refined processes developed

• Into early 2000 most Prepreg came from large, established “Prepreg manufacturers”

• In last 10 years newer, specialty Prepreg companies established that provide smaller batches, custom formulations. (i.e., Aldila, Renegade, Patz, Park)


Prepreg Markets Today

• Resin formulators are increasing in number and scope, offering complete tested systems with documented performance

• There have been over 35 companies in China alone who are entering carbon fiber manufacturing

• Today most Prepreg comes from dedicated materials suppliers (e.g. Toray, Hexcel, Gurit, Cytec) or are manufactured and consumed with in large production companies

• Smaller quantity consumers and custom material users pay higher prices and wait longer for their materials


Prepreg from a Suppliers Perspective

What Suppliers Want:

• Large production runs

• Standard material types

• Standard resin types and formulations

• Standard material configurations – resin content, roll lengths, poly backing

• Long lead times

• Higher profits


Prepreg from a User’s Perspective

What Users Want:

• Short production runs

• Customized resin systems

• Adapted material properties based on use, time of year, etc.

• Short lead times

• Lower costs

• Changing or custom configurations

• Flexibility

• Own or leverage Intellectual Property (IP)


Why “On Demand Prepreg” is now Possible

Convergence of four factors:

1) Advancements in Resin system formulations making them easier to use

2) Growth of resin formulators and availability of custom resins systems

3) Processing knowledge more available

4) Automation systems have now matured so they can monitor, control, record and repeat key process parameters


Benefits of making your own Prepreg

1. Ability to produce low-temperature-curing prepregs physically close to end use

2. Avoid limitations of major Prepreggers product range

3. Avoid being pushed to bottom of list behind larger customers

4. Quick-turnaround R&D tool

5. Lead-time improvements

6. Waste reduction


Benefits of making your own Prepreg (cont.)

7. Ability to match physical properties to requirements

8. Reduction/elimination of refrigerated storage

9. Competitive advantage and protection of critical IP

10. Improved Time-to-Market

11. Unique Product offerings

12. Cost reduction


Key issues to Consider

• Amount of Prepreg required

• Widths and types of Prepreg required

• Material specifications and Qualifications

• Expertise in company on Prepreg production


Full costing example

Prepreg Cost & Output Calculator for CDI 1370mm Off-line Filming Package Fiber areal weight 150gsm hours/day 16 Sqm/hour 320.0 days/week 5 Sqm/day 5,121 weeks/year 30 Sqm/year 768,096 Fibre price input USD$/kg $25.00 Direct Costs USD$/SQM $3.03 Resin content by wt. (%) 35 Indirect costs USD$/SQM $0.23 Materials USD$/SQM $6.70 Labor rate (fully-loaded) USD$/hr. $65.00 Depreciation (accelerated, years) 5 MANUFACTURING COST / SQM $9.96 Current Purchase cost USD$/sqm $20.00 Potential savings per year USD$ $7,710,206

Based on initial capital cost of Complete Prepreg Workcell:

Net Present Value of Project*: $13,080,760.95 Internal Rate of Return: 93%

(*NPV assumptions: 10% opportunity cost of capital, 5-year term with IRS MACRS depreciation schedule, 35% corporate tax rate)


Conclusion

• Making Prepreg on-demand is now a viable option

• Automation and advancements in resin chemistry make this possible for “non-experts”

• Custom resin formulations can be purchased or mixed on-site

• There are numerous benefits to be realized, with cost not always the driving reason

• Time-to-market, speed of innovation, ability to customize and flexibility are tomorrow’s competitive advantages


For more information on making your own prepreg

Please contact us at:

[email protected]

(858) 292-1212

mailto:[email protected]

Www.centurydesign.com On Demand Prepreg. Agenda History of Prepreg Prepreg markets today Prepreg...

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