1. What trends and perspectives for the automation of the composite market ? What are the advantages of the automation of processes in the composites industry ?

2. MATRASUR Composites Making composites easier o A Company of o Supplying the composites market since 1972 o + 400 machines configurations o + 5 500 installed units o + 1 100 customers worldwide 2 Norican Group Shaping Industry

3. Automation in the Composites industry: Facts & perspectives Facts: o Composite products suffer from excessive labor costs Perspectives: o Automation potentials remain high and under investigated 3

4. Robotics : A new tool for the industrialization of composites Some figures: o Number of robots installed per year o Robot population per 10,000 workers in the manufacturing industry 4 (source “World robotics 2007”)

5. Composites & Industrialization Potentials for automation today: o Potentials offered by the industrialization of composites are high as they still remain poorly investigated to this date o This potential represents with no doubt the best source of improvement for competitiveness o Automation contributes to a sustainable development approach Potentials for automation today: o Potentials offered by the industrialization of composites are high as they still remain poorly investigated to this date o This potential represents with no doubt the best source of improvement for competitiveness o Automation contributes to a sustainable development approach 5

6. Industrialize, yes, but How? o By rethinking o By rethinking the production methodology modernizing it o By modernizing it current and future environmental requirements a sustainable development o By considering current and future environmental requirements towards a sustainable development 6

7. Main steps of the industrialization process o Exhaustive audit o Exhaustive audit of methods, technical resources and skills o Analysis of production goals o Analysis of production goals (quantity, quality, economical, ergonomics, ecological aspects…) technical solutions o Review of all technical solutions choices o Technical and economical choices > financing o Comprehensive engineering study and implementation planning o Implementation o Exhaustive audit o Exhaustive audit of methods, technical resources and skills o Analysis of production goals o Analysis of production goals (quantity, quality, economical, ergonomics, ecological aspects…) technical solutions o Review of all technical solutions choices o Technical and economical choices > financing o Comprehensive engineering study and implementation planning o Implementation 7

8. o Multi-competent engineering resources: mechanics, automatism, robotics o Software: 2D and 3D Cad software, robotic dedicated software, Visual Basic o Feasibility studies and development o Complete integration & turn-key approaches o Programming capacities o Multi-competent engineering resources: mechanics, automatism, robotics o Software: 2D and 3D Cad software, robotic dedicated software, Visual Basic o Feasibility studies and development o Complete integration & turn-key approaches o Programming capacities Process Engineering Key elementsInternalorExternalresourcesInternalorExternalresources 8

9. Developing competencies: Training on material and processes Training on Mechanics & Hydraulics Training on Automatism & Programming Training on Maintenance Production start-up support and follow-up 9

10. Industrializing Composites through Robotics o Handling systems o Release agent spray-up o Gelcoat spray-up (single or multi color) o Barrier-Coat spray-up o Resin spray-up o Chopped lamination o Paint spray-up o Roll-out o Insert positioning o Adhesive lay down o PU foam spray-up o Resin cast on press o Trimming, machining, surface grinding o Fiber placement Robotic solutions now available for : All workshop sectors are concerned! 10

11. Industrializing Composites through Robotics 11 Traditional Mode versus Robotic Mode

12. Robotics for composites industries Robotics for composites industries Industry fields already using Robotic solutions for composites: o Automotive industry: Spray-up, trimming, adhesives… o Aerospace industry: Fiber placement, part trimming and finishing... o Industrial parts: Spray-up, trimming,.. o Boat industry: Gelcoat, barrier-coat and release agent spray-up o Sanitary ware: Handling systems, spray-up, part trimming, insert positioning… o Rail Industry: Trimming of parts for High Speed Trains (TGV) o Water treatment: Spray-up of reservoirs and filters o Swimming pools and Spas: Spray-up of pool shells, trimming o Energy: Wind blades coating 12

13. Case studies o Turn Key robotic system for a GRP Pool manufacturing Plant o Industrializing production in a Small Size Company 13

14. Industrial production line for GRP pools : Encountered problems: o Creation of a new production site o Unexperienced staff with respect to the product o Limited workshop surface o Desire to have a highly automated solution o Desire to have a total control over production costs 14

15. Industrialized process: o Robotic spray-up of release agent o Robotic multicolor gelcoat spray-up o Robotic barrier-coat spray-up o Robotic chopped laminate spray-up o Production flow management on carousel Industrialized process: o Robotic spray-up of release agent o Robotic multicolor gelcoat spray-up o Robotic barrier-coat spray-up o Robotic chopped laminate spray-up o Production flow management on carousel Industrial production of GRP pools BEFORE/AFTER 40h 13h /Pool (-70%) o 40h Labor/ Pool brought down to: 13h /Pool (-70%) 320,000 € (-12%) o Yearly raw material cost savings : 320,000 € (-12%) o Significant increase in: Product, quality, working conditions… 15

16. Spray-up robot for release agent, gelcoat barrier-coat Resin&fiberglass spray-up robot Automatic conveyor Curing zone Part demoulding Transfer 16

17. Case study 2 o Industrialization & (Very) Small Size Companies 17

18. Small Size Companies on the path of industrialization o Large variety of parts o Small series o Limited personnel o Company oriented towards “hand made” work o No 3D drawings available o Undefined company strategy o Short term vision Problems faced: 18

19. Robotic becomes accessible: Low Cost Robot now available 19 M a t e r i a l M i x M u l t i c l o l o r g e l c o a t U n i t C h o p p e r u n i t A u t o m a t i c p u m p f e e d i n g S e n s o r c o n t r o l l e d E x h a u s t P a r t L o a d i n g S a f e E n c l o s u r e R o t a t i n g 7 t h A x i s L i n e a r 8 t h A x i s F i l t r a t i o n R o v i n g f e e d i n g P C C o n t r o l s P a r t I d e n t i f i c a t i o n P a r t p o s i t i o n n i n g B r i d g e C r a n e R o b o t A n t i c o l l i s i o n s a f e t y d e v i c e M a t e r i a l T ° c o n t r o l

20. Robotic becomes accessible: Programming now simplified 20 Step1 Programming Step2 Producing

21. Phase 1: Robot for acrylic reinforcement with system based on teach-through robot Phase 2: Robot for part trimming and drilling with offline programming system Small size companies on the path of industrialization: Technological evolution step by step 21

22. How robotics brings Sustainable Development Benefits to composites shops

23. Robotics : transforming composite workshops 23

24. Reducing production surface for significant energy costs reductions o VOC’s exposure at lowest (no personnel in lamination areas) o No more dangerous nor painful work stations o No more dust nor chemical residues in the workshop 24

25. Concentrated VOCs are easier to treat Effluent treatment now affordable (less air volume for a higher VOC concentration) o Photo-catalytic treatment o Charcoal filtration o Incineration o Etc.. 25

26. Minimized extraction volumes in smokestacks o Extraction directly from VOC source for a minimized extracted volume o Air exhaust from VOC source for ventilation control through sensor o Better control of VOC effluents preserves workshop surrounding environment 26

27. ECONOMICAL ASPECTS o Productivity, cost effectiveness, Raw material Savings Competiveness o Production Management o Increased quality o Reduced production surface Energy Cost reduction ENVIRONMENTAL ASPECTS o Working Conditions significantly improved o Reduced Air exhaust Volumes & VOCs in Stacks o Affordable VOCs treatment o Lower Energy requirement o Affordable Regulation compliance Robotics : transforming composite workshops 27

28. An unexpected opportunity for combining quality, productivity and sustainable development while satisfying the highest standards requirements Robotics applied to composites: 28

29. www.matrasurcomposites.com Thank you for your attention