1. Composites: Materialising a better future
Composites: Materialising a better future. Obstacles and opportunities & How African companies can tap into the global composites supply chain
Prof. K. Kanny
Composites Research Group
Department of Mechanical Engineering
Durban University of Technology
Tel: ; Fax:

2. Composite: Structural
Particle-reinforced
Fiber-reinforced
Structural
• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º or 0/45/90º
-- benefit: balanced, in-plane stiffness
• Sandwich panels
-- low density, honeycomb core
-- benefit: light weight, large bending stiffness
honeycomb
adhesive layer
face sheet
Adapted from Fig ,
Callister 7e. (Fig is
from Engineered Materials
Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
Adapted from Fig , Callister 7e.

3. OBSTACLES
Production capabilities-There are no automated processors available to manufacture small and complex components to high quality standards and volumes.
The majority of composites manufacturing is dependant on manual labour and craftsmanship skills
High material costs-
Constituent materials can be costly for the process.
fibre production- inhibits high volume deployment
The process of fiber preparation
like embedding fibres in matrix, cutting,
drying and synthesizing for processors like layup,
fiber winding and pultrusion is hugely expensive

4. OPPORTUNITIES
Light weight high strength and corrosion resistant products
Less fuel consumption & road damages
Less CO2 emission
Greater use of automation to improve cycle times
out-of-autoclave tooling
New and novel processing techniques –
integration of natural fibers, bio-resins, and other “green” materials
development of other high performance exotic material systems

5. Synthesis of a Natural Resin System
Cavendish
Biocomposite
V.Paul, K.Kanny, GG Redhi “Formulation of a novel bio-resin from banana sap” Industrial Crops and Products

6. Wheat Protein Isolate for Packaging Application
GREEN POLYMERS
Wheat Protein Isolate for Packaging Application
WPI
Glutaraldehyde
Glycerol
NaOH
Nano
GREEN POLYMERS
Dani. Jagadeesh, B. Prem Kumar,, Jong IL Song Preparation and Properties of Propylene Glycol Plasticized Wheat Protein Isolate Green Films,
Journal of Polymers and Environment (2013) 21(4):930–936.

7. Processing Thermoset processing SMC Fiber spraying
Resin Transfer Molding
Thermoplastic processing
putrusion
Extrusion compression
Injection molding
Compression molding
thermoforming
Resin transfer molding

8. Fiber treatment
Clay infusion+ alkali, silane, acetylation, grafting and maleated coupling

9. BIOCOMPOSITES Natural Fibers Natural Resins systems SKATEBD DIVING BD
TROLLEY

10. Natural fiber products prepared at our CRG centre, DUT
Banana fiber extraction and knitting
Threading and strand making
Vacuum infusion of fiber mat
Fiber mat epoxy composites

11. How Africa can be part of the global composites supply chain
continuous development of new product & processes
Africa benefits from export of large natural resources require innovation in processes and product
beneficiation of natural resources
access to unlimited markets- globalisation
specialisation and the reaping of scale economies
enhance production capabilities (exploiting the benefits of cluster dynamics and supply chain linkages
the development of local supply chains
the development of industrial clusters and supply chain upgrading
beneficial insertion into global value chains
Co-location - generates external economies
enhances the competitiveness of firms in the cluster.
build on these external economies
cooperate to meet common challenges
benefit from collective efficiency  

12. STRUCTURE & ANALYSIS
IN-HOUSE BUILD MOULD DESIGN AND MANUFACTURING FOR HIGH IMPACT RESISTANCE
Manufacturing of a Train nosecone demonstrator
Work on the adaptation of a sisal plain weave (furnishing fabrics) for composite application

13. Air box as installed on the aircraft engine
COMPOSITE AIR BOX FOR AIRCRAFT ENGINE: TECHNOLOGY DEMONSTRATOR – RESIN VACUUM INFUSION FOR COMPLEX SHAPED COMPOSITE PARTS USING ADDITIVE MANUFACTURED TOOLING
Tooling – inner and outer tools for the bottom section of the airbox
Dry- fibre preforms loaded into the bottom section outer tool
Air box as installed on the aircraft engine

14. Composite Pedestrian Bridge

15. Composite Housing
Slide by A. Madiba

17. CONCLUSION
Composites based product manufacturing possess many challenges in production capabilities, production cost and high raw material cost.
Equally there are many opportunities and scope for a variety of new fit for purpose applications includingthe use of biopolymers and natural fibers for biocomposites
With the advent of nanofillers as a reinforcement the scope has widen
The high cost may be mitigated by greater market penetration and economies of scale