Category: News

The global carbon fibre and composite materials community is set to converge in Geelong in 2023 for the biennial Carbon Fibre Futures Conference.

Tickets are now on sale for the conference, which will be held at Waurn Ponds Estate, Geelong, Australia on 8-10 May and hosted by Carbon Nexus, Deakin University’s world-class carbon fibre and composite materials research facility.

This will be the first time the conference has run since the pandemic and will explore the latest developments in carbon fibre and composite materials from across the globe in what has been described as a ‘unique convergence of industry, academia and applied research’.

‘The Carbon Future Fibres Conference is a bespoke conference that will showcase the carbon fibre and composite materials research that is happening here at Deakin University and around the world,’ says Professor Russell Varley, group leader at Carbon Nexus.

‘This conference is ideal for those who want to come to Australia, see our world-class research and create networks in this emerging and important field.

‘For more than 10 years we have run this conference and it has built itself a reputation as a quality conference for carbon fibre and composite materials.’

So far guest speakers include top experts in the fields of carbon fibre and composite materials; Professor Leif Asp of Chalmers University of Technology, Professor Véronique Michaud of Ecole Polytechnique Fédérale de Lausanne (EPFL), Professor Adrian Mouritz of RMIT University, and our own Professor Minoo Naebe.

The conference will also include seminars presented by the top experts from Deakin University, Carbon Nexus and local industry partners that will discuss the tools needed to create successful industry university collaborations.

Furthermore, a limited number of attendees can put the knowledge they have gained from the conference into practice with a unique carbon fibre manufacturing Workshop at Carbon Nexus where they will get ‘hands-on’ training at the research-scale on the fibre spinning and carbonisation manufacturing lines.

The conference is currently calling for abstracts that can address the following themes:

• Manufacturing and processing of carbon fibre
• Advances in carbon fibre recycling and sustainability
• Innovative Carbon Materials of the Future
• Modelling and Composites Characterisation
• New Precursor Technologies
• Surface Modification and Carbon Fibre Characterisation
• Functional Carbon Fibres and Composite Materials

Abstract submissions close on Friday 24 February.

To learn more about the conference, sponsorship or submitting an abstract, click here.

Material scientists at Deakin University enhance performance and extend service life of pipelines and offshore infrastructure for a more sustainable future.

Deakin’s Institute for Frontier Materials researchers, in collaboration with researchers from PETRONAS Research and the University of Adelaide, have scooped the IChemE Malaysia Awards 2020, Oil and Gas Award for their project Metal Organic Framework as Self-Healing Catalyst during the organisation’s first ever virtual ceremony.

The IChemE Malaysia Awards celebrate excellence and innovation in various fields of chemical engineering and is an excellent avenue for teams, companies or individuals to have their projects recognised on an international platform.

Since starting in 2006, IChemE Malaysia Awards have seen a growing participation from various industries and hope to see this trend continue in coming years to showcase and encourage more collaboration between STEM professionals so that chemical engineers remain at the forefront of innovation.

The new work by Professor Russell Varley, Dr Jane Zhang and Dr Mandy De Souza from the Institute for Frontier Materials (IFM) develops a novel self-healing epoxy that delivers a highly robust and reliable performance when added to the interior of steel pipes in oil field operations.

These methods ensure the integrity of materials during operation, which could lead to longer service life of the materials and cost avoidance for maintenance and inspection by about 80 per cent.

Professor Varley said this win is a recognition of the novel and sustainable aspects of this research and showcases the importance of this technology for better futures.

“This technology developed in conjunction with PETRONAS and Professor Christian Doonan from the University of Adelaide, has the potential to extend service life, reduce consumption and improve resource efficiencies in infrastructure applications.”

“We are excited to be working with PETRONAS to create new technologies which are helping them transition to a more sustainable future,” said Professor Varley.

Importantly, this technology offers a better performing and sustainable alternative by replacing the precious rare-earth-based catalyst and preserving the Earth’s resources. Now with an economically viable option, this work has addressed the main challenge of current microencapsulation healing technologies for generations to come.

For more information:

Professor Russell Varley is a Professor of Composite Materials at Deakin University’s Institute for Frontier Materials.

Dr Jane Zhang is a Research Fellow in Composites at Deakin University’s Institute for Frontier Materials.

Dr Mandy De Souza is a Senior Research Fellow at Carbon Nexus in carbon fibre composites within Deakin University’s Institute for Frontier Materials.

Researchers at Carbon Nexus are supporting a project to study the feasibility of Artificial Intellingence (A.I.) solutions for the interpretation of composite testing data.

The project, led by the Advanced Fibre Cluster Geelong, and funded under a Defence Science Institute (DSI) Smart Ideas Grant, will investigate AI solutions for composite materials integrity testing – in collaboration with global leader in carbon fibre wheels, Carbon Revolution, and Deakin University’s world-class researchers.

The DSI Smart Ideas Grant is awarded to SMEs with innovative defence research ideas, who seek university and inter-industry collaboration to further their R&D. Designed to alleviate the financial obstacles that businesses can face when entering defence research, for AFCG the DSI grant will support feasibility research towards the goal of solving manufacturing process challenges for composites manufacturers.

Led by cutting edge A.I. researchers at Deakin University’s Applied Artificial Intelligence Institute (A²I²), and supported by composites experts from Carbon Nexus, the project will look at how recent advances in machine learning can make step changes to current approaches in quality assurance testing of composite components and structures.

The research aligns with the DSI’s goals of encouraging and facilitating innovative collaborations that will deliver enhanced national security.

DSI’s Craig Butler commented:

“Advances in manufacturing techniques and the use of new materials are very relevant for Defence across a range of areas. This is an important study and we are pleased to support the AFCG and their research and industry partners in helping to develop sovereign capabilities to better understand the behaviour and performance of composite materials for Australian Defence applications.”

 

Carbon Revolution’s head of Engineering and Design, Dr Ashley Denmead, said:

“Innovation and improvement are at the heart of our business of supplying the highest performing wheels to some of the most prestigious automotive manufacturers in the world. The rigor of aerospace processes is a critical part of what we do. This new research is part of our continuous quest to remain the global leaders in our sector.”

 

Carbon Nexus Professor of Composite Materials, Professor Russell Varley, said:

“Applying artificial intelligence techniques to enhance the interpretation of non-destructive composites testing methods has the potential to speed the process as well as improve the quality of the analysis. Faster and more accurate testing and inspection of composite structures is a key requirement for a number of our industry partners including defence, aerospace, automotive and alternative energy generation.”

 

CEO of the Advanced Fibre Cluster, Jennifer Conley, said:

“The Deakin University researchers leading this project are testing the feasibility of emerging technologies that have huge potential for the composites industry. Advanced fibre composite materials have contributed to the development of aerospace, defence and mobility for more than 50 years – making more and more things possible in terms of design, durability, and light weighting – but challenges remain. The AFCG is extremely proud to be able to support their ground-breaking work.”

 

Currently, inspection to ensure integrity, composition, or condition of composite structures involves using either X-ray or ultrasonic scanning. X-ray based testing is expensive in terms of both capital and operational investment.  Sound-based testing systems are relatively more portable and cost-effective but do not offer the scan resolution provided by the radiation testing.

The AFCG project with Deakin’s world-class A.I. and composite researchers and Carbon Revolution aims to investigate how machine learning can resolve these challenges, bringing significant value to defence and advancing Australia’s sovereign capabilities.

Carbon fibre is regarded as one of the lightest and strongest materials on Earth. Compared to a unit of steel, carbon fibre is up to ten times stronger, two times stiffer, and 66 per cent lighter.

Carbon fibre composites manufacturers now have access to a new technology that decreases oxidation process time from 80–110 minutes down to less than 15 minutes, making it possible to produce 360% more carbon fibre by volume in less time and with lower capital and energy costs. The technology, which was developed by Deakin University has since been licensed to LeMond Carbon. An article about the scale-up of the new technology by LeMond was recently published in Aerospace Manufacturing and Machining Magazine. Read more

LeMond Carbon has announced the results of an independent technical audit conducted by Bureau Veritas (BV) of its revolutionary carbon fibre manufacturing process.

The audit was conducted on the Carbon Nexus pilot line.

The total oxidation time and material properties verified by BV support LeMond’s claims to lower costs and significantly increased output versus traditional carbon fibre technology.

Bureau Veritas, a company founded in 1828, is today a world leader in laboratory testing, inspection, and certification services.

Widely regarded as a trusted brand synonymous with quality, BV are highly experienced at auditing innovative technologies and manufacturing processes.

For the audit of LeMond’s technology, BV measured total oxidation times of sub-15 and sub-20 minutes over two separate production campaigns of 24K standard modulus (SM) carbon fibre, achieving fibre tow properties in excess of 270 GPa tensile modulus and 3,500 MPa tensile strength.

The BV audit was conducted on Carbon Nexus’s 100 metric ton pilot line which is currently producing samples for trials with LeMond’s target customers in several SM industrial markets.

In addition to accurately measuring oxidation times and assuring process traceability, BV oversaw the fibre sampling, packaging and shipping of audit samples for extensive testing at the BV laboratories in Pessac, France.

Composite tow tests of the LeMond fibre were completed according to ASTM D 4018-17 standards.

LeMond and Deakin University are teamed to commercialise this innovative technology which enables reductions of 75% and 70% in capex and energy consumption per kilo of output respectively.

The rapid oxidation process enables LeMond to produce carbon fibre with the lowest embodied energy of any standard PAN-based carbon fibre available today.

‘This is a significant milestone for our company. Having our technology independently verified by BV validates the revolutionary nature of our technology,” said Greg LeMond, Founder and Chairman of the Board of LeMond Carbon.

“My team and I are excited to bring our high-performance low-cost carbon fibre to the global market, and look forward to expanding into new markets where the current high cost of carbon fibre has been a significant barrier to adoption.”

“Deakin has always been excited about the potential of our patented new technology and it is encouraging to receive independent validation that our technology is effective at scale,” said Mr LeMond.

“We look forward to continuing to support LeMond as they commercialise a lower-cost and lower-emission carbon fibre,” said Derek Buckmaster, Director Carbon Nexus.

Having proven the capability to successfully produce a competitive standard modulus carbon fibre, LeMond has launched a new capital raise to develop a 5,400-metric ton production facility in Oak Ridge, Tennessee.

To date, parent LeMond Companies LLC has raised approximately USD 18.6M of seed capital from individual and institutional investors, including Deakin University.

Deakin University has welcomed the appointment of leading advanced manufacturing advocate and strategic communications specialist Jennifer Conley as CEO of the Advanced Fibre Cluster Geelong.

The Advanced Fibre Cluster Geelong (AFCG) is an initiative from a group of highly innovative Geelong companies, with the goal of establishing the region as a global centre of excellence for advanced fibre and composites innovation.

The Cluster is led by the Geelong Manufacturing Council with support from Deakin University and engineering firm Austeng.

Ms Conley will support Cluster members in generating new opportunities and investment for their businesses and the Geelong community. Other such dedicated cluster initiatives have been shown to be highly successful in spurring the commercialisation of new technologies, and creating new revenue streams for companies and their wider regions.

Deakin Carbon Nexus Director Derek Buckmaster, who is a member of the AFCG board, said the Cluster had entered a new phase with Ms Conley’s appointment.

“We are very excited to welcome Jennifer to this new role,” Mr Buckmaster said.

“Jennifer’s credentials as a leader in the field of industry and research collaboration, and her work boosting innovation and Australian success in advanced manufacturing, are well known.”

Ms Conley comes to the AFCG following two decades working at the intersection of industry, research and government. From 2011 to 2017 she was chief strategy designer, then inaugural Executive Director, for the Australian Advanced Manufacturing Council – Australia’s first private sector initiative supporting the emerging advanced manufacturing sector.

“I am very excited to be contributing to some of the most innovative companies and organisations in the advanced manufacturing sector in this country,” Ms Conley said.

“These are creative companies gaining access to high value global supply chains with new solutions and products. Deakin’s role has been pivotal in the development and acceleration of advanced fibre technology so it is perfect that the Cluster will be based out of Deakin’s ManuFutures building.

“We know from international experience that clusters work best when there is a geographic concentration – people share knowledge and transfer ideas when they are part of a neighbourhood, and there is a sense of ideas and solutions flowing more freely. I think we’ll see lots of new opportunities developing out of the Cluster over the next couple of years.”

Research group leader at Carbon Nexus, Professor Russell Varley said it was very exciting to see the carbon fibre cluster gaining momentum.

“I have no doubt that the collaborations established as a result of Jennifer’s arrival will have a great impact on the region,” he said.

The appointment was made possible thanks to a $300,000 Victorian Government grant. The State Government investment was bolstered by a $200,000 combined commitment from Deakin, which is a foundation partner, together with the City of Greater Geelong and the Geelong Manufacturing Council.

Carbon Nexus director, Derek Buckmaster has been honoured for his contribution to Australia’s place on the world stage.

Mr Buckmaster, whose leadership and experience within the composites, plastics, petrochemicals and automotive sectors has seen Carbon Nexus established as one of the world’s most advanced fibre research centres, has been announced as the winner of the Advance Awards‘ Advanced Manufacturing Award category for 2018.

Now in its seventh year, the Advance Awards celebrate international Australians, those living abroad and those who have returned home following high achievement overseas, who exhibit remarkable talent, exceptional vision and ambition.

Mr Buckmaster, Carbon Nexus Director and Management Committee Chair, has worked in numerous countries including China, Japan, Singapore, The Netherlands, Saudi Arabia and the United States.

Before coming to Deakin in 2014, Mr Buckmaster led the Functional Polymers business unit of Saudi diversified manufacturing company SABIC, and spent 19 years with GE Plastics in various roles including marketing, product development, application technology, sales, information technology and Six Sigma.

He said it was an honour to be recognised by Advance for Carbon Nexus’ work in the global carbon composites sector.

“At Carbon Nexus it’s important to approach our research and our advanced manufacturing from a global perspective. We’re connected into a global market, and a global carbon fibre industry that’s growing at a great rate, with more and more companies starting to make use of lightweight material technologies.

“The impact this will have across a wide range of industries over the coming decade is profound, and the work we’ve been undertaking for these past four years has placed Carbon Nexus at the core of one of Australia’s most significant investments in global technology, developing the people and research base that will shape our world in years to come,” Mr Buckmaster said.

“We had high expectations when we first set out with Carbon Nexus, and I’m proud of how our team has delivered on what was promised, to become one of the world’s leading carbon fibre research facilities, playing a role in re-inventing Australia’s manufacturing industry for the modern era.”

Established in 2014 with support and investment from Deakin and all levels of government, Carbon Nexus is the world’s first open access, dedicated pilot scale research plant capable of producing large-scale quantities of industrial and aerospace quality carbon fibre.

Home to the only polyacrylonitrile (PAN) precursor wet spinning line in the Southern Hemisphere, a research line for small quantities of carbon fibre and innovative research activities, and a pilot scale line, which produces sample quantities of carbon fibre for industrial scale evaluation, Carbon Nexus offers R&D services from precursor development to white fibre spinning, to carbon fibre production and composite manufacturing.

Mr Buckmaster’s award caps off a string of recent successes for Carbon Nexus, with the signing of a $58 M deal with LeMond Composites last year to revolutionise the use of carbon fibre across the world, and the facility being named the 2017 winner of the Powercor Geelong Business Excellence Awards Innovation, Research and Development category.

Advance is an initiative supported by Australian Government funding and the Advance Awards cover categories from education, sustainability and the arts to financial services and technology innovation.

Mr Buckmaster was presented with his Award on 18 October 2018 at Sydney Town Hall.

Carbon Revolution and Deakin University collaborate to deliver innovative and advanced manufacturing technologies for composite wheel technology for the global automotive industry

Today’s announcement of a new $15m manufacturing research and development project, facilitated by the Innovative Manufacturing CRC (IMCRC), signals the future for the Australian automotive manufacturing industry.

The $15m project will see Australian-based automotive technology company, Carbon Revolution, collaborate with researchers from Deakin University in a unique partnership to develop innovative and advanced manufacturing technologies.

According to Carbon Revolution’s Chief Executive Officer, Jake Dingle, this research project will support a significant increase in terms of industrial scale and output of its products, which are exported to markets around the globe.

“The research outputs from this project are closely aligned with Carbon Revolution’s future development plans to invest in developing new innovative manufacturing technologies and material science, and we’re thrilled to be able to work with Deakin University on this project.” Mr Dingle said.

Head of the IMCRC, David Chuter, said that this research project was a great example of the potential benefits Australian manufacturers could enjoy if a collaborative approach to innovation, between industry and research organisations, was adopted.

“The IMCRC’s focus is on catalysing tangible, commercial outcomes for Australian manufacturers, by bringing together manufacturing businesses and research organisations, to support innovations that will ensure the Australian manufacturing industry can meet the challenges and opportunities presented by today’s global economy,” Mr Chuter said.

“IMCRC’s $3m contribution to this three-year research project is catalysing both investment in manufacturing technologies, as well as facilitating a dedicated Carbon Revolution and Deakin co-located Innovation Space which will be created within the new Carbon Revolution facilities, scheduled for completion later this year,” said Mr Chuter.

Mr Dingle said that he was also optimistic about the technological impact, and anticipated commercial outcomes, of this significant R&D collaboration.

“This project has the potential to take our technology more rapidly to the next level, which will further strengthen our global leadership and competitiveness in the area of composite wheels,” Mr Dingle said.

“We are already recognised as the global leader in this space thanks to our design and engineering capabilities, and the focus for this next critical phase is to fully industrialise and scale up our manufacturing processes and operations.”

The research will take place at a dedicated collaborative Innovation Space and R&D Lab, on site at Carbon Revolution located within the Deakin Waurn Ponds Campus, and will bring together some of the best minds in carbon fibre product development, materials science and manufacturing innovations.

Professor of Composite Materials at Deakin’s Institute for Frontier Materials, Russell Varley, is part of the steering committee leading the $15M dollar research project.

“Deakin is excited to partner with Carbon Revolution to make composite materials that are more processable, more durable, stronger and tougher, at lower cost,” Professor Varley said.

“The technology developed in this project will ensure Deakin and Carbon Revolution remain at the leading edge of global composite materials research, particularly in relation to lightweight structures, raw materials and fabrication technologies.”

The research project intends to catalyse change across a range of key commercialisation and industrialisation drivers, including:

• Research into raw material inputs, such as resin system development and fibre development
• Composite system elements and advanced process developments
• Manufacturing process automation and industrialisation
• Research into the integration of intelligent manufacturing and Industry 4.0
• Establishment of a new Innovation Space and R&D Lab

For more information, or to coordinate interviews with a representative of the IMCRC, Carbon Revolution or Deakin University, please contact:

Jana Kuthe, IMCRC, +61 416 735 666,                                       jana.kuthe@imcrc.org

Steven Gunzburg, Civic Reputation, +61 423 766 021           steven.gunzburg@civicreputation.com.au

Carbon fibre composites are set to improve the performance of wind turbines and benefit the local and global renewable energy sector.

Deakin University is partnering with leading wind energy solution provider Vestas, to improve the compressive strength of carbon fibre composite materials for wind turbines.

Deakin Carbon Nexus Director Derek Buckmaster said that along with the potential to improve wind turbine performance, the partnership underscored possible expansion of Geelong’s composite research and manufacturing footprint and would help Victoria achieve its Renewable Energy Target (VRET).

“We are delighted to work with Vestas to achieve these goals,” Mr Buckmaster said. “The combination of Deakin’s research expertise from the world-leading composites research team at Carbon Nexus, and Vestas’ industry capabilities has the potential to take composite materials research to the next level, delivering real-world outcomes for Victoria.”

Carbon fibre composites are a critical material to the further improvement of wind turbine blades, due to their unmatched strength-to-weight ratio, enabling the manufacture of longer blades which improve efficiency and lower cost.

The uptake of carbon fibre composites has been one of the main drivers behind the increased turbine efficiency and competitiveness of wind power in recent years. Turbine blades are now the largest single use for carbon fibre, accounting for over 40 per cent of global production.

Dr Adrian Gill, global lead specialist for blade structure and material at Vestas, noted the importance of investing in further materials research.

“With carbon fibre composite innovations, we can increase the performance of turbine blades. Stronger carbon fibre will allow us to reduce the required amount of carbon fibre used in the blade, so the blade will be lighter and cheaper. This makes renewable energy cleaner and more affordable and supports the development of Australia’s growing wind energy sector,” Dr Gill said.

Vestas Asia Pacific President Clive Turton highlighted the importance of the Victorian Government’s renewable energy targets and auction strategy to the local renewable energy industry.

“Improved composite material will bring revolutionary benefit to renewable industry locally and globally. By improving efficiency and driving down the cost of wind turbines, we are providing Victoria, Australia and the world with clean and more affordable energy,” Mr Turton said.

“Breakthroughs in composite materials will benefit the wind industry and may deliver significant commercial outcomes in other industries.”

“Our new partnership leverages Deakin’s leadership in carbon fibre composites and Vestas’ expertise as a leading global player in the wind energy sector. It is a powerful combination that will position Geelong and Victoria at the forefront of wind energy innovation and commercialisation.”

The $34m Carbon Nexus research facility has already attracted many local innovative carbon fibre parts manufacturers, such as Carbon Revolution and Quickstep, and global carbon fibre manufacturer LeMond.

With strong State Government support, Geelong is fast becoming a globally relevant centre of excellence for composite research and advanced carbon fibre-based manufacturing. The research with Vestas is conditional on awards to Vestas Supported Projects under the Victorian Renewable Energy Auction Scheme.

Deakin University will partner with leading wind energy solution provider, Vestas, to improve the compressive strength of carbon fibre composite materials for wind turbines.

Deakin Carbon Nexus Director Derek Buckmaster today joined Head of Vestas Australia and New Zealand, Peter Cowling and Minister for Energy, Environment and Climate Change the Hon. Lily D’Ambrosio at the University’s Waurn Ponds Campus for an official signing agreement to collaborate to develop better and stronger materials in Victoria.

Mr Buckmaster said that along with the potential to improve wind turbine performance, the partnership underscored possible expansion of Geelong’s composite research and manufacturing footprint and would help Victoria achieve its Renewable Energy Target (VRET).

“We are delighted to work with Vestas to achieve these goals,” Mr Buckmaster said.

“The combination of Deakin’s research expertise from the world-leading composites research team at Carbon Nexus, and Vestas’ industry capabilities, has the potential to take composite materials research to the next level, delivering real world outcomes for Victoria.”

Carbon fibre composites are critical material to the further improvement of wind turbine blades, due to their unmatched strength-to-weight ratio, enabling the manufacture of longer blades which improve efficiency and lower cost.

The uptake of carbon fibre composites has been one of the main drivers behind the increased turbine efficiency and competitiveness of wind power in recent years. Turbine blades are now the largest single use for carbon fibre, accounting for over 40 per cent of global production.

Vestas Asia Pacific President Clive Turton noted the importance of the Victorian Government’s renewable energy targets and auction strategy to the local renewable energy industry.

“Improved composite material will bring revolutionary benefit to renewable industry locally and globally. By improving efficiency and driving down the cost of wind turbines, we are providing Victoria, Australia and the world with clean and more affordable energy,” Mr Turton said.

“Breakthroughs in composite materials will benefit the wind industry, and may deliver significant commercial outcomes in other industries.”

“Our new partnership leverages Deakin University’s leadership in carbon fibre composites and Vestas’ expertise as a leading global player in the wind energy sector. It is a powerful combination that will position Geelong and Victoria at the forefront of wind energy innovation and commercialisation.”