Primary Skills
What we do
We are a leading consultancy on all aspects of all polymeric materials.
- We specialize in Composites (fibre reinforced polymers):
- Both thermoset and thermoplastic.
- Material Characterization.
- Material Selection.
- Material Qualification.
- Design.
- Product and Materials Development.
- Process Certification.
- New Product Introduction.
- Manufacturing & Mould Tooling.
- Non-destructive testing.
- Destructive testing.
- We also consult on both engineering thermoplastics such as PEEK and commodity thermoplastic such as polyethylene.
- We consult on both highly regulated and low technology industries.
- We consult on product and process improvement and optimization.
Past assignments
My assignments have been varied in terms of industries and content. While I have worked in all fields of polymers I have specialized in Composite Materials and am at the forefront of the technologies involved ranging from design and materials science through manufacturing and tooling to product assurance and project management.
Industries
- Aerospace – fixed wing – Boeing, Airbus, GKN, Pilatus, Bombardier.
- Aerospace – rotary wing – Hughes Helicopter, Westland.
- Automotive – Jaguar LandRover, Aston Martin.
- Industrial – Bridon Bekaert Ropes, Slingco Cross Arms.
- Research – NCC plus many other industrial organisations throughout the years.
Countries worked and lived in
- USA
- Canada
- Australia
- South Africa
- Indonesia
- Europe – Switzerland, Norway, Spain, Germany, France, UK
Examples of projects
- Recovered 6 months production from a faulty Autoclave:
- Mapped out position of moulds in the autoclave and took samples from offcuts from components in expected cooler areas.
- Cured research samples at various steps above and below the target cure temperature.
- Tested all sample using SBS, Tensile strength and flexure, DSC, DMA.
- Cleared (approved) 98% of the output to the satisfaction of the FAA.
- Qualified a Hexcel carbon/Epoxy prepreg:
- Manufactured some 5% of the coupons which were tested by Hexcel.
- This data was combined with Hexcel data to qualify the prepreg for use by the client.
- Researched techniques to improve the plastic sheathing of steel and synthetic fiber ropes:
- Introduced new super thick Polyethylene sheathing.
- Designed the extrusion die.
- Specified the processing parameters.
- Supervised the initial production.
- Introduced new super thick Polyethylene sheathing.
- Managed the design and sourced all the body panels for the Aston Martin DBX prototype:
- Made the body panels from glass/vinyl ester wet lay-up:
- Roof and windscreen from toughened glass:
- Underbody panels from thermoformed Polypropylene:
- Bumpers from thermoformed Polycarbonate:
- Directed the initial design of electricity power distribution Cross -Arms including forensic analysis of competitors products:
- Optimized the design using FEM and materials selection of Composite material box sections filled with PU foam.
- Assisted with the outsourcing of the manufacture of pultruded hollow box section beams in glass fibre/epoxy.
- Researched the processing of PEEK polymer for a wing leading edge.
- Researched into the Airbus “Wing of the Future programme” at the National Composites Center using novel techniques.
Personal Profile
I have some 30 years’ experience of Composites and Polymeric Materials in general and have worked for most the aerospace and automotive OEMs plus several general engineering organizations. On graduating with a Masters in Polymer Engineering from Cranfield in 1980 I progressed to Production & Production Engineering Manager for Composites and Metal Bonding at BAe Space Division prior to going freelance some 6 years later. I have been freelancing ever since.