2. The Problem The Problem
Hardcore Composites currently uses a VARTM process to create bridges, marine applications, and custom molding.
vacuum
part
vac-pot

3. 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.

4. Customers & Wants Customers & Wants Customers: Wants:
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%)

5. Constraints Constraints
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

6. Metrics Metrics Metrics Target Values Span 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

7. Benchmarking Benchmarking
Current technology: No VARTM recycling exists!
Competitors:
Companies that use or sell VARTM processes for comparable products
Palmer Manufacturing & Supply
Center for Composite Materials
Advanced Process Technology
Companies that sell liquid transfer process components

8. Concept Tree Concept Tree valves check manual relief
sensors/monitoring
weight float switch auto
2-chamber
load - lock
gas delivery
flow meters regulators
tubing
connections
1-chamber
pots
seals lining protection brackets

9. Concepts
vacuum
vent
vent
part

10. vacuum 28”
vacuum <28”
vent
part

11. Chosen Concept

13. Testing
Testing
Check Valves
Feasibility Model
Sensors

14. Prototype
Prototype

15. Schedule
Schedule