Introduction

The Closed Mould Alliance, an innovative partnership between Alan Harper Composites, Tower Composites, and Ilium Composites, stands at the forefront of the UK composites industry. United by a commitment to superior quality, efficiency, and sustainability, the Alliance will showcase its groundbreaking technologies at the ICS show in Milton Keynes, September 4-5, 2024, where the team will be available on Stand R6. These companies offer a comprehensive suite of solutions that revolutionise composite manufacturing by reducing waste, enhancing part quality, and improving operational efficiency.

Vision and Mission

The Closed Mould Alliance aims to be the leading resource for manufacturers seeking to adopt innovative closed moulding processes that deliver environmental, economic, and operational benefits. By leveraging its partners’ collective expertise and advanced technologies, the Alliance will drive sustainable practices within the composites industry.

Partners in Innovation

Alan Harper Composites

Alan Harper Composites is the market leader in reusable silicone technology for composite moulding. With over 15 years of pioneering experience, the company offers an extensive range of products, including moulding supplies, the latest generation of silicone spray machinery, high-quality platinum cure silicone, and world-class training. The company has revolutionised the industry with its custom-designed silicone membranes, which replace traditional vacuum bags or B counter moulds.

Key Offerings

Reusable Silicone Technology

Alan Harper Composites’ membranes are crafted to fit the A side mould (base) precisely and can withstand 400 to over 1,000 moulding cycles. This technology eliminates the need for single-use consumable bagging materials, drastically reducing operational waste. The enhanced compaction effect also improves glass-to-resin ratios, producing more robust, higher-quality products using less resin. The result is a more sustainable production process with a reduced net part weight, which is beneficial for end-of-life disposal.

Wide Applicability

While particularly appealing to vacuum infusion moulders, reusable silicone technology offers significant benefits for hand lamination operators and other closed moulding practices such as RTM and Light-RTM.

Enhanced Efficiency

The reusable silicone system allows for faster setup and turnaround times. In a recent survey, 72% of participants cited efficiency and time savings as the primary reasons for their interest in the reusable process. For instance, Notus Fan in South Africa reported dramatically reducing setup time from 60 minutes to just 5 minutes. This efficiency and improved process control lead to better quality outcomes and more predictable material forecasts.

Environmental Impact

The technology’s ability to eliminate single-use plastics and reduce resin consumption contributes significantly to sustainability. For example, a single silicone membrane can be used for over 400 cycles, potentially removing the equivalent number of disposable vacuum bags.

Tower Composites

Tower Composites is a technical multi-market moulder specialising in glass fibre composite moulding parts for diverse automotive, marine, and construction industries. The company has integrated advanced reusable vacuum tooling systems that streamline production processes, minimise waste, and enhance product quality.

Key Offerings

Reusable Vacuum Tooling Systems

Tower Composites employs cutting-edge reusable vacuum tooling systems, significantly reducing reliance on single-use consumables like plastic films and bagging materials. This approach minimises environmental waste and enhances precision and repeatability in production, leading to superior final products. The use of reusable silicone vacuum bags, in particular, allows for quick tooling changes, making the process more adaptable to varying customer needs and reducing the overall production time.

Diverse Product Range

As a technical multi-market moulder, Tower Composites produces a wide array of glass fibre composite parts that serve various sectors, including automotive, construction, and marine. Their ability to deliver customised solutions tailored to specific industry requirements sets them apart. Whether for lightweight components in automotive applications or durable parts in marine environments, Tower Composites’ products meet the stringent demands of modern engineering.

Sustainability Focus

Tower Composites is deeply committed to sustainability in its operations. By adopting reusable vacuum tooling systems, the company has made significant strides in reducing waste, particularly in minimising the excess material often associated with traditional RTM and LRTM processes. This focus on sustainability lowers production costs and aligns with the broader industry trend towards greener manufacturing practices.

Ilium Composites

Ilium Composites manufactures and distributes high-quality fibreglass reinforcements using unique process technology. Their state-of-the-art manufacturing capabilities and mechanical binding system produce superior resin flow and surface finish. Ilium’s stitch-free and chemical binder-free technology reduces time and costs while ensuring high-quality finished parts, positioning the company as a leader in the GFRP industry.

Key Offerings

High-Quality Fiberglass Reinforcements

Ilium Composites specialises in producing advanced fibreglass reinforcements, which are essential for creating high-performance composite materials. Their flagship products, including the FLEXmat® and ULTImat® series, are designed to improve composite parts’ mechanical properties and surface finish, making them ideal for applications in construction, automotive, and marine industries.

Mechanical Binding System

One of Ilium’s most innovative developments is its mechanical binding system, which replaces traditional chemical binders and stitching. This system ensures better compatibility with a wide range of resins, improving the composite material’s structural integrity and overall quality. The absence of chemical binders also makes the process more environmentally friendly, reducing the emission of volatile organic compounds (VOCs) during production.

Efficient Manufacturing

Located in Bahrain, Ilium Composites operates a highly automated manufacturing facility capable of producing over 15,000 tons of fibreglass reinforcements annually. Their efficient production processes ensure consistent quality and reduce energy consumption and waste. This commitment to efficiency enables Ilium to offer competitively priced products without compromising performance.

Commitment to Sustainability

The Closed Mould Alliance is passionate about improving and promoting sustainable practices within the composites industry. Each partner contributes unique expertise and innovative solutions that collectively reduce waste, improve efficiency, and enhance the quality of composite parts. The Alliance’s technologies align with several Sustainable Development Goals.

Environmental Benefits

Immediate Waste Reduction

Using reusable silicone membranes significantly reduces the consumption of single-use consumable materials like plastic film, peel ply, and resin-locked flow mesh. For example, a single silicone membrane can replace 1,000 instances of single-use plastics.

Enhanced Part Quality

Improved material consolidation and reduced resin usage result in parts with a 10-30% lower material contribution. This reduction not only conserves resources but also facilitates easier end-of-life disposal.

Lower Carbon Footprint

Innovations contribute to more sustainable manufacturing practices by reducing waste and improving production efficiency.

Future Developments and Innovations

Advancements in reusable silicone technology, such as the introduction of the Morph and Micro-Morph resin runners, integrate flow paths behind the reusable membrane moulding surface. These products have become client favourites due to their ability to streamline the infusion process while maintaining high-quality outcomes.

This development, combined with plans for expansion into new territories, underscores the Alliance’s commitment to driving the future of composite manufacturing.

Industry Applications and Customisation

The Closed Mould Alliance’s technologies are highly adaptable and are customisable to meet the specific needs of various industries, from automotive to marine. For example, the Dutch marine manufacturer Interboat has successfully transitioned from LRTM processes to reusable closed mould technology, significantly saving resin usage and production time.

Each project begins with thoroughly assessing the client’s moulding setup and material requirements. The Alliance’s technical team provides bespoke support to ensure successful implementation and ongoing system optimisation.

Case Studies and Industry Adoption

Adopting Alan Harper’s innovative reusable silicone technology has led to significant advancements across several key industries, particularly in marine, automotive, and aerospace manufacturing. Companies within these sectors have experienced notable improvements in efficiency, cost savings, and environmental sustainability, reinforcing the value of transitioning to more sustainable composite manufacturing processes.

Notus Fan (South Africa):

Notus Fan, a leading manufacturer of industrial ventilation systems, integrated Alan Harper’s reusable silicone technology into their production line to improve the efficiency of their composite moulding processes. By replacing traditional vacuum bagging techniques with reusable silicone membranes, Notus Fan achieved a dramatic 55-minute reduction in setup time per cycle. This improvement increased their overall production capacity and allowed for greater flexibility in meeting the varying demands of their clients. The enhanced compaction effect of the silicone membranes also improved the quality of the composite fan blades, resulting in a longer lifespan and better performance of the final products.

Interboat (Netherlands):

Interboat, a renowned Dutch luxury yachts and boats manufacturer, transitioned fully to reusable silicone systems, marking a significant milestone in their commitment to sustainable manufacturing. By adopting Alan Harper’s reusable technology, Interboat reduced resin usage by up to 25%, leading to substantial cost savings in material expenditure. Additionally, the switch to reusable systems resulted in a reduction of over 50% in waste generated from single-use bagging materials. The environmental impact was minimised as the company decreased its reliance on volatile organic compounds (VOCs), enhancing workplace safety and contributing to a lower overall carbon footprint. The transition has also allowed Interboat to streamline its production processes, enabling quicker turnaround times for custom yacht orders without compromising quality.

Conclusion

The Closed Mould Alliance represents a powerful collaboration to redefine the composites manufacturing landscape. By combining the expertise and innovative technologies of Alan Harper Composites, Tower Composites, and Ilium Composites, the Alliance is driving forward a more sustainable, efficient, and high-quality approach to composites production. Visit us at the ICS show in Milton Keynes to discover how the Closed Mould Alliance can help you mould smarter and enhance your operations.