Evaluating The Performance And Cost Of Infusion

Evaluating the Performance and Cost of Infusion Ramesh Watson

What will we cover today? 

Introduction of DIAB



Brief from Client to DIAB



Past and current global DIAB infusion projects



Project recommendations  Weight Study  Proposed hull laminates  Cycle time study  Process study  Cost study  Implementation plan



DIAB marketing support  How to market benefits of sandwich and infusion construction



SUMMARY

Who is DIAB 

1200 employees globally



World leader in sandwich structural cores  #1 in foam structural core manufacturing capacity  #2 in Balsa manufacturing capacity  #1 in sandwich technology  #1 in core infusion technology



Brands include  Divinycell®  ProBalsaTM  DiviletteTM  DIAB Core Infusion TechnologyTM  DIAB TechnologiesTM

Brief from Client to DIAB 

Client will give DIAB all the necessary data required for the 36ft Motor Yacht Hull and would like DIAB to:  Estimate what the current hand laminated hull should weigh  Put forward a proposal on converting manufacturing process to

INFUSION using DIAB Core Infusion TechnologyTM .  Propose structural and laminate redesign for INFUSION for hull.  Propose infusion strategy, materials selection, build/labour time

estimates, build/labour/materials cost estimate. 

When approved, Client will work with DIAB under contract to implement and supply technology, training and materials.

Global DIAB infusion customers “DIAB has converted more production boat manufacturers to infusion than any other company” 

Company  Azimut  Gobbi  Sunseeker  Fiart  Sealine  Nimbus  NuMarine

Company:AZIMUT    

Location: Range: No.of employees: Models infused:

Italy 39 to 116ft 1000 AZ40

AZIMUT: 

DIAB involvement:  Redesign of laminates and structure from single-skin hull to a

fully cored hull.  Training of production staff  Production implementation  AZ40 Model now in production  Marketing and dealer training support (never marketed cored

hull)  Supply of pre-cut infusion core kits  Implement infusion of other models in range eg. 42, 50, 55, 62,

65ft

AZIMUT: Why infusion? Employee benefits:  Solve OH&S issues  Improve skills of staff

Environment benefits:  Reduce VOC emissions

Brand benefits:  Improved quality and repeatability  Improved performance and marketability

AZIMUT: Why infusion? Financial benefits:  Improve staff retention  45% faster than hand lamination on 40 to 55ft range  25% labour reduction on 40 to 55ft range  Lift valuation of company

AZIMUT: 55ft deck

Company:Gobbi    

Location: Range: No.of employees: Models infused:

Italy 39 to 55ft 350 39 Atlantis

Company:SUNSEEKER    

Location: Range: No.of employees: Models infused:

England 28 to 105ft 1400 65ft (Hull and Deck)

Company:Nimbus    

Location: Range: Boats per year: Models infused:

Sweden 28 to 42ft 50 of Nova 35 Nova 35 (Hull)

Company:SEALINE     

Location: Range: Boats per year: No.of employees: Models infused:

England 25 to 60ft 400 700 S29 (Hull)

Company:FIART    

Location: Range: Boats per year: Model infused:

Italy 22 to 50ft 500 38ft Genius (Hull)

36ft Motor Yacht Hull  Findings

and recommendations

 Proposed hull laminates  Weight Study  Cycle time study  Process study  Cost study  Implementation plan

Laminate Comparison PART

ORIGINAL HAND LAMINATE

DIAB INFUSION LAMINATE

Hull Bottom 900 600 1868 600 1868 900

CSM CSM DUOMAT CSM DUOMAT CSM

900 750 600 26mm 1050 750

Sprayed Rovings Triaxial Biaxial Divinycell H100 Biaxial Triaxial

CSM CSM COREMAT CSM CSM QUAD CSM CSM COREMAT CSM

900 750 600 15mm 1050 750

Sprayed Rovings Triaxial Biaxial Divinycell H80 Biaxial Triaxial

CSM CSM WR CSM WR CSM PLY CSM PLY CSM

1050 1050 750 600 1050 1050 40mm 40mm 1050 1050 1050 750 1050 1050

Biaxial Biaxial Triaxial Biaxial Biaxial Biaxial Divinycell H130 Divinycell H200 inserts Biaxial Biaxial Biaxial Triaxial Biaxial Biaxial

Hull Side 900 600 2.5mm 600 600 800 600 600 2.5mm 600 Transom 900 900 800 900 800 600 19mm 600 19mm 900

Laminate Comparison PART

ORIGINAL HAND LAMINATE

DIAB INFUSION LAMINATE

Keel 900 600 1868 600 1868 900 3368

CSM CSM DUOMAT CSM DUOMAT CSM 50% Overlaps

900 750 600 600 1050 600 1050 600 1050 600 1050 600 1050 600 1050 750 600

Sprayed Rovings Triaxial Biaxial CFM Biaxial CFM Biaxial CFM Biaxial CSM Biaxial CFM Biaxial CFM Biaxial Triaxial CFM

Bulkheads 1200 CSM 12mm PLY 1200 CSM

800 Biaxial 15mm Divinycell H80 800 Biaxial

Preliminary Weight Estimate Original Hand Laminate

1643 kg DIAB estimate (1760kg actual avg)

Preliminary Weight Estimate DIAB Core Infusion Laminate 1024 kg

Preliminary Weight Estimate – A Global Comparison DIAB Core Infusion Laminate 1024 kg

Original Hand Laminate Weight difference: 1643 – 1024 = 619 kg (38% reduction) 17 components removed

1643 kg

New Longitudinal Girder Structure

New Longitudinal Girder Structure

Structural Arrangement – Proposed Longitudinal Girders 

Dispose transverse floors



Structural efficiency  Less weight for given strength  Provides direct support to panels AND contributes to the

longitudinal strength  Transverse strength provided by bulkheads and decks 

Structural continuity  Minimises abrupt changes in stress levels



Utilisation of space  Less interference

Preliminary Weight Estimate – A Part For Part Overview Hull Bottom

Keel

Bulkheads

Hull Side

Transom

Preliminary Weight Estimate – A Part For Part Comparison Weight Comparison of Hull Panels 450 400

Weight [kg]

350 300 250 200 150 100 50 0

Hull bottom

Hull side

Transom

Keel

Bulkheads

Original Hand Laminate

341.10

420.00

140.89

66.54

186.84

DIAB Infusion Laminate

247.66

247.56

92.52

73.03

64.86

Reduction

27%

41%

34%

+10%

65%

Preliminary Weight Estimate – A Part For Part Comparison Weight Comparison of Panel Components 1400 1200

Weight [kg]

1000 800 600 400 200 0

Total

Glass

Resin

Core material

Original Hand Laminate

1155.37

359.77

585.06

173.22

DIAB Infusion Laminate

725.64

288.38

273.37

126.56

Reduction

37%

20%

53%

27%

Weight Saving Benefits – Performance Overview Original: ∆ = 9.50 tonnes

DIAB Infusion: (- 619 kg)

∆ = 8.88 tonnes

P = 472 kW (total installed)

P = 441 kW (total required)

2 x 239 kW

2 x 239 kW

MerCruiser @ 100% MCR

MerCruiser @ 85% MCR

V = 35.0 knots

2 x 239 kW MerCruiser @ 100% MCR

V = 37.4 knots

Weight Saving Benefits – Performance Overview Cummins MerCruiser 4.2L EI 320 250

80 70

200

60 50 40

100

30 20

50

10 0 0

1000

2000

3000 RPM

4000

0 5000

85% MCR l/hr

kW

150

100% MCR Power Fuel

Weight Saving Benefits – Performance Overview Original:

DIAB Infusion:

70 L/hr @ 3900 RPM, 236kW

40 L/hr @ 3300 RPM, 220kW

90% Tank Capacity Per Engine = 360 L

Range:

Range:

333 km @ 35 knots

583 km @ 35 knots

Weight Saving Benefits – Summary Less Weight means:  Lower fuel consumption  Longer range  More speed  Quieter operation  Better acceleration  Better maneuverability  Boat planes quicker

Design Rules – A Brief Outline Minimum Requirements

Part

AS4132

DNV

ISO

DIAB

Outer skin laminate g/m2

1580

2400

1260

2250

Inner skin laminate g/m2

1264

1600

882

1800

--

H130

--

H100

AS4132

DNV

ISO

DIAB

Safety Factors Core

type

Part Laminate

S.F.

3.5

3.34

2

AS4132

Core

S.F.

2.9

2.5

2

AS4132

Process And Application – Original Hand Lay-up Day 1 Stage

1

2a

2b

3a

3b

4

5a

5b

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time

30

45

90

60

90

20

90

90

90

Men

1

1

0

3

0

1

3

0

3

1 Preparation of mould 2a Gelcoat 2b Wait for gelcoat to dry 3a Application of tie layer 3b Wait for tie lay to dry 4 Grinding of dags off the laminate

5a Port topside, bottom, keel and entire transom laminate B applied 5b Wait for port side to dry 6 Starboard topside, bottom and keel lamination

Process And Application – Original Hand Lay-up Day 2 Stage

7a

7b

8

9

Time

90

90

90

30

Men

3

0

3

2

7a Starboard side 2nd laminate 7b

Wait for starboard side to dry

8 Port side 2nd laminate 9 Bogging keel and strakes

Process And Application – DIAB Infusion Day 1 Stage

1

2a

2b

3a

3b

4

5

Time

30

45

90

60

90

20

285

Men

1

1

0

3

0

1

2

1 Preparation of mould

3b Wait for tie lay to dry

2a Gelcoat

4 Grinding of dags off the laminate

2b Wait for gelcoat to dry

5 Load kitted fabric for outer skin

3a Application of tie layer

Process And Application – DIAB Infusion – Day 2 Stage

6

7

8a

8b

8c

9

10

Time

240

320

60

60

45

60

30

Men

2

2

2

4

4

3

2

6 Load kitted core materials 7 Load kitted girders and fabrics 8a Set out reusable resin feed and vacuum lines 8b Fit pre-fab vacuum bag to mould and connect to catch pots and pump system

8c Drop test and leak finding, set up resin 9 Start infusion and fill part 10 Remove bag and lines

Processing And Application – The Bottom Line Build time for hand laminate process = 23.5 man hours (2 days) Build time for DIAB infusion process = 28.4 man hours (2 days)

Processing And Application – Future Optimisation Tie Layer Obsolescence = Deduct 2.5 man hours Optimal Infusion Time = Deduct 0.3 man hours Optimal Setup Time = Unlimited

Polyworx Infusion Simulation - The Setup

Polyworx Infusion Simulation - Open Resin Lines

Polyworx Infusion Simulation - 8.29 mins (35% filled)

Polyworx Infusion Simulation - 14.3 mins (50.2% filled)

Polyworx Infusion Simulation - 18.4 mins (75.1% filled)

Polyworx Infusion Simulation - 42.1 mins (Complete)

Cost Study 

Assumptions  Used provided cycle and labour times for current hull  Used material costs provided by Distributors  Used 5% wastage and labour @ $60/hr  Construction up to hull shell and bulkhead components  No rework costs for hand lay-up hull included  No consumables for hand lay-up and infusion processes included

Current hand lay-up hull= ~$5,000 DIAB infusion hull= ~$13,500 Cost difference= ~$8,500 Weight difference= 619kg

Cost Study – The important questions 

How do you manage the cost differential between existing fabrication method and infusion method?  Revise cost-to-weight targets for this model? What are acceptable trade-offs?  Revise material selection to achieve cost for weight target?  Reduce engine specification to maintain price point?  Utilise integrated benefits in the market place for differentiation?  Lower running costs  Better performance (power-to-weight ratio, maneuverability)  Better build quality  Better end-user comfort

Market differentiation Features and benefits of Divinycell® sandwich construction to the end-user/owner:  Lighter weight construction allows either:  Reduced fuel usage for same power (lower fuel cost/greater range)  Greater fuel capacity (improved range)  Greater thermal and acoustic insulation. Eliminates condensation.

   

Reduces heating and cooling energy requirements, while providing greater comfort to the user. Larger span between inside frame work, means more usable volume. Improved safety from hull impact penetration due to double-skin construction. Additional in-built buoyancy provided, adding to safety. Eliminates ‘structural timber-rot”, therefore improving long-term retained value of the vessel for the owner.

Implementation Plan - Hull 

Next steps:  Classification decision (Client)  Cost/performance targets (Client)  Cost/performance engineering (Client /DIAB)  Factory setup (Client /DIAB)  Materials qualification (Client /DIAB)  Team training: Stage 1 (Client /DIAB)  Team training: Stage 2 (Client /DIAB)  Infuse hull#1 (Client /DIAB)  Implement plan for other parts (Client /DIAB)  Dealer training

Single Skin Infusion – An Brief Overview



Use the hull bottom panel for example



Benchmark against DIAB Infusion laminate



Offer two options for Single Skin Infusion

Single Skin Infusion – An Brief Overview DIAB Infusion Laminate - Hull Bottom 900 g/m2Sprayed Rovings

Results

750 g/m2Triaxial

Panel Size

1200 x 600 mm

600 g/m2Biaxial

Total Thickness

31.00 mm

Panel Weight

10.97 kg/m2

Mid-panel Deflection

2.86 mm

26 mmDivinycell H100 1050 g/m2Biaxial 750 g/m2Triaxial

Single Skin Infusion – An Brief Overview Option A – Reduced Panel Size 900 g/m2Sprayed Rovings 450 g/m2CFM 750 g/m2Triaxial

Results

450 g/m2CFM

Panel Size

600 x 600 mm

Total Thickness

9.91 mm

Panel Weight

15.76 kg/m2

Mid-panel Deflection

10.92 mm

1050 g/m2Biaxial 450 g/m2CFM 600 g/m Biaxial 2

450 g/m2CFM 1050 g/m2Biaxial 450 g/m2CFM 750 g/m2Triaxial 450 g/m2CFM

Single Skin Infusion – An Brief Overview Option B – Equivalent Panel Size 900 g/m2Sprayed Rovings 450 g/m2CFM 750 g/m2Triaxial 450 g/m2CFM

Results

750 g/m2Triaxial

Panel Size

1200 x 600 mm

Total Thickness

12.46 mm

450 g/m2CFM

Panel Weight

19.91 kg/m2

600 g/m2Biaxial

Mid-panel Deflection

10.49 mm

450 g/m2CFM 1050 g/m2Biaxial

450 g/m2CFM 1050 g/m2Biaxial 450 g/m2CFM 750 g/m2Triaxial 450 g/m2CFM 750 g/m2Triaxial 450 g/m2CFM

Single Skin Infusion – Summary

Single Skin Infusion means: 

More glass required to achieve required thickness



Additional weight from extra stiffeners (Option A)



Heavier panel



Greater deflection



Engineering overkill