On Demand Prepreg
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Agenda
• History of Prepreg
• Prepreg markets today
• Prepreg from a Suppliers perspective
• Prepreg from a User’s perspective
• Why “On Demand Prepreg” is now possible
• Key issues to consider
• Conclusion
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History of Prepreg
History of Prepreg
• First Prepreg machine developed in 1969 to support carbon tape for NASA lunar lander
• Resin systems were difficult to use, mix, catalyze, process consistently, control tack, etc.
• Prepreg processing machines employed by end users for their own materials
• Materials suppliers started providing prepregs (e.g. Narmco, Fiberite, Ciba)
• New resins, materials and refined processes developed
• Into early 2000 most Prepreg came from large, established “Prepreg manufacturers”
• In last 10 years newer, specialty Prepreg companies established that provide smaller
batches, custom formulations. (i.e., Aldila, Renegade, Patz, Park)
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Prepreg Markets Today
• Resin formulators are increasing in number and scope, offering
complete tested systems with documented performance
• There have been over 35 companies in China alone who are
entering carbon fiber manufacturing
• Today most Prepreg comes from dedicated materials suppliers
(e.g. Toray, Hexcel, Gurit, Cytec) or are manufactured and
consumed with in large production companies
• Smaller quantity consumers and custom material users pay higher
prices and wait longer for their materials
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Prepreg from a Suppliers Perspective
What Suppliers Want:
• Large production runs
• Standard material types
• Standard resin types and formulations
• Standard material configurations – resin content, roll lengths,
poly backing
• Long lead times
• Higher profits
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Prepreg from a User’s Perspective
What Users Want:
• Short production runs
• Customized resin systems
• Adapted material properties based on use, time of year, etc.
• Short lead times
• Lower costs
• Changing or custom configurations
• Flexibility
• Own or leverage Intellectual Property (IP)
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Why “On Demand Prepreg” is now Possible
Convergence of four factors:
1) Advancements in Resin system formulations making them
easier to use
2) Growth of resin formulators and availability of custom resins
systems
3) Processing knowledge more available
4) Automation systems have now matured so they can monitor,
control, record and repeat key process parameters
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Benefits of making your own Prepreg
1. Ability to produce low-temperature-curing prepregs physically
close to end use
2. Avoid limitations of major Prepreggers product range
3. Avoid being pushed to bottom of list behind larger customers
4. Quick-turnaround R&D tool
5. Lead-time improvements
6. Waste reduction
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Benefits of making your own Prepreg (cont.)
7. Ability to match physical properties to requirements
8. Reduction/elimination of refrigerated storage
9. Competitive advantage and protection of critical IP
10. Improved Time-to-Market
11. Unique Product offerings
12. Cost reduction
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Key issues to Consider
• Amount of Prepreg required
• Widths and types of Prepreg required
• Material specifications and Qualifications
• Expertise in company on Prepreg production
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Full costing example
Prepreg Cost & Output Calculator for CDI 1370mm Off-line Filming Package
hours/day
days/week
16
5
Fiber areal weight
Sqm/hour
Sqm/day
weeks/year
30
Sqm/year
Fibre price input USD$/kg $25.00
Resin content by wt. (%)
35
Labor rate (fully-loaded) USD$/hr. $65.00
Depreciation (accelerated, years)
5
150gsm
320.0
5,121
768,096
Direct Costs USD$/SQM
$3.03
Indirect costs USD$/SQM
Materials USD$/SQM
$0.23
$6.70
MANUFACTURING COST / SQM
Current Purchase cost USD$/sqm
Potential savings per year USD$
Based on initial capital cost of Complete Prepreg Workcell:
Net Present Value of Project*:
Internal Rate of Return:
$9.96
$20.00
$7,710,206
$13,080,760.95
93%
(*NPV assumptions: 10% opportunity cost of capital, 5-year term with IRS MACRS depreciation schedule, 35% corporate tax rate)
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Conclusion
• Making Prepreg on-demand is now a viable option
• Automation and advancements in resin chemistry make this
possible for “non-experts”
• Custom resin formulations can be purchased or mixed on-site
• There are numerous benefits to be realized, with cost not always
the driving reason
• Time-to-market, speed of innovation, ability to customize and
flexibility are tomorrow’s competitive advantages
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For more information on making your own prepreg
Please contact us at:
Info@CenturyDesign.com
(858) 292-1212
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