DIAB Divinycell Kits Guide - DIAB Knowledge Series

7/26/2019 DIAB Divinycell Kits Guide - DIAB Knowledge Series

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Optimize your kitBoost your performance

Improve efficiency,lower cost andincrease quality

DIAB Knowledge Series


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Taking your specific goals into account, you can signifi-

cantly improve the manufacturing performance and quality

of composite applications by receiving core material

delivered in pre-cut parts (kits) instead of just plain sheets.

DIAB is a world-leading supplier of sandwich composite

solutions with long experience in developing kits for the

composite industry worldwide. We offer this knowledge

guide to help you achieve the best results with your kits

based on our expertise and experience with a variety of

segments over the years. Kits are far from off-the-shelf,

one-size-fits-all solutions. This guide is a springboard for

detailed discussions that we as experts would like tohave with you to find an optimal solution to fit your needs.

What is a kit?With DIABs kit concept, each piece is pre-cut and

shaped as necessary and then numbered to fit exactly

into its designated place in the mold. The kit can consist

of everything from sheets only to 3D shapes made with

CNC routing. Kits are designed based on customer

requirements for weight, cost and quality, as well as taking

geometry, manufacturing process and lay-up sequence

into account.

Why do kits matter?By eliminating the on-site shaping and cutting of flat

sheets, you can reduce build times and save labor and

Design the optimal kit

to boost your performanceWhat would it take to boost your applications performance? Lower weight or cost? Increased manufacturing

efficiency and quality? Most likely it is a specific combination of several strategic criteria.

Pinpointing your needs

for efficient customizationDifferent customers have different requirements for success in their markets. That is why it is so important to have

a detailed run-through of your needs at the start, and to maintain a close dialogue during the entire kit process.

Based on our experience, we have identified four major

groups with similar needs in regards to kits. This insight

enables us to quickly zero in on your requirements and

provide targeted advice for customizing your optimal kit.

Yet, with almost limitless nuances, no needs are the

same. This means that what makes an optimal kit differs

material cost. In addition, with the easy assembly and

exact fit, you can achieve a consistently high quality in

less time.

Boost performance in terms of weight, cost and quality

Shorten lay-up time of the core in the mold

Improve surface quality and decrease weight

Minimize the amount of waste handling

Reduce material stocks

How DIAB can help

Everything under one roofWe understand that application objectives differ from

customer to customer. That is why our kit offering is

scalable and flexible. Having core, finishing and kit design

under one roof enables us to optimize lead times,

streamline logistics costs and provide high service levels.

Defined process based on long experience

Working with kits demands a close cooperation between

customer and supplier, with continuous evaluation and

possibility for improvements. To support this, DIAB uses

a defined kit process that enables us to provide

competitive offerings, top service and quick turn-around

times for prototypes. You define which parts of the

sequence you will manage or let DIAB manage. Naturally,

the highest value you gain from working with DIAB is to

let us provide a full s olution from concept to ready kit.

from customer to customer. However, the processes and

criteria impacting kit design are the same for all customers.

Therefore, to ensure we develop kits according to your

needs, we always go through the same process to identify

and discuss the impacting criteria with you as a customer.

Quality

Cost

Medium-volume, smallermarine and compositeapplications

Wind blades and high-volumecomposite applications withhigh demands on durability

Larger series marine andtransport applications withhigh quality requirements

High-performanceapplications with complexgeometry; subsea, racing andaerospace applications

Surface finish

Weight

Manufacturing

Geometry

Applications with similar kit requirements

Composite process

Optimizedkit

Courtesy:Fairline

Courtesy:Hallberg&Rassy

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Customer manufacturing operationsThe type of manufacturing operations you run influence

the way the kit is designed and manufactured. For example,

one-offs, luxury yachts or large serial production of wind

blades each have quite different impacts on the kit type.

It is also important for us to know how you work as it

provides invaluable information on how to pack and

sequence the kit in the best way significantly impacting

efficiency in your manufacturing.

Composite manufactur ing processThe process you use in your manufacturing also impacts

the design and manufacturing of the kit. The process

defines what finishing is used in the kits as well as how

important the tolerances are when joining the kit parts

together in the mold. The main groups of manufacturing

processes are:

Open molding:When using open molding, the tolerances

on the kit parts are usually less critical compared to closed

molding techniques.

Infusion:When using infusion processes, there are moreconsiderations to be made. The kit parts need to fit perfectly

to each other on a variety of surfaces and geometries.

Resin Transfer Molding (RTM):Since RTM includes two

stiff counter molds, it is essential to have a perfect match

between core and mold to optimize resin consumption

and ensure consistency over a production run.

Two categories influencing kit designAnalyzing the two main influencing categories key success criteria and technical drivers will help you work

with our experts to develop the kit best suited to improving your applications performance.

As you begin to evaluate and make decisions based on the various factors within these categories, our

cooperation is critical to understanding that they relate in unique ways depending on the type of application

meaning that each factor can influence the others. The following pages will give you a good basis for

understanding and discussing the impact these factors have on your kit design.

Surface finishSurface requirements differ and affect the approach we

take for kit design. On a wind blade, the durability is more

crucial than the surface finish. Compare this with a racing

or luxury yacht and you have different alternatives for

how to arrange the sheets in the kit, as well as different

finishing. Using Kit Lok, for example, improves surface finish

as the good fit between kit parts reduces the risk of "race

tracking" or surface printing from resin. Understanding

your requirements ensures focus is placed in the right areas .

QualityQuality level is naturally an important success criterion.

Depending on the type of application, operational require-

ments and expected operational lifetime, it has a significant

impact on kit design.

CostCost is an essential part of the whole kit process.

Understanding and going through your requirements and

what will impact the kit ensures that the kits costing is

accurately based on what you need.

WeightIn weight-sensitive applications, a lot of focus is placed

on having as much of the application designed with sand-

wich as possible, including angles. Where weight is not

Manufacturing and geometry are important keys to unlocking the right kit design for maximum efficiency and

quality in your application. It is vital to address these factors as early as possible in the process.

GeometryGeometry has a significant impact on the kit related to

material selection and the time it takes to design and

manufacture the actual kit. Discussing your requirements

with DIAB at an early stage in the applications design

phase will help ensure the kit meets the geometry

requirements of the component.

What are the key success criteria for your application?? What are the technical drivers for your application??

There are four main factors to consider: surface finish, weight, quality and cost. Most likely, you will have a

combination of requirements for your application so it is important to understand how each one influencesthe others to determine how your application is positioned overall for these criteria.

Corner with single skin:

heavier

Corner with bevels:

full sandwich, lighter

DIAB's Kit Lok ensures sheets are bondedtogether with perfect precision.

so critical, single skin could be used in complicated parts

of the application to save cost and speed up fitting.

Depending on the corner, we can apply multiple solutions

for optimizing weight or cost.

DIABs Kit Lok concept ensures tight connection and

that kit parts stay steady in the mold.On flat parts of the

application, the kit parts fit well together based on the

kits fine cutting. Good fit decreases weight as it prevents

gaps from filling with resin.

When weight is critical, you should also focus on optimal

finishing. For instance, you should use different types of

finishing for the core dependent on the applications

shifting geometry.

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Optimizedkit

Designing an optimal kitWe know that customer needs vary. That is why we provide solutions rather than products. When working with

kits, our customers have the opportunity to fully utilize DIABs expertise and competence, or to fill in certain parts

of the process with their own key competence. Below, you see all the el ements needed to reach an optimal kit

according to your requirements. DIAB can assist you in all these activities or just a few the choice is yours.

Structural design

and core selectionBased on the loading requirement in the finished part,

DIAB can assist you in the structural design. This includes

selecting the most appropriate core corresponding to

the loading requirement, as well as producing the laminate

design. To optimize weight and cost, we select cores

that are the best fit for structural demands.

Composite

manufacturing processDepending on the type of application, a number of different

manufacturing processes may be applicable. DIAB can

work with you to recommend a process as well as provide

training and help to set up the process that is best suited

for your application.

Customer-specified kit DIAB optimized kit

The kit design

Finishing selectionFinishing has a distinct and profound impact on your

applications success directly influencing weight, cost and

quality. Your design objectives, manufacturing process,

and the geometry of your application all play important

roles in determining which finishing options to use. DIAB

helps you choose from a wide range of cuts, grooves,

perforations, kerfs, etc. in different patterns, each serving

a specific purpose to optimize your application.

Nesting/optimizing

Nesting means to strategically place the kit parts on a

square sheet to maximize material yield and reduce waste.

Larger and fewer kit parts optimize cost as they increase

the yield. During nesting, we take the handling of the kit

in the fitting process into consideration. This ensures the

kit is as easy to use as possible, while providing the most

economical solution. We strongly recommend to all cus-

tomers that DIAB always handle this part of the process

as we have the correct tools and expertise for getting this

exactly right.

Kit manufacturingDIAB has all the necessary tools and machines to cut the

kit according to your design, yielding high quality, speed

and consistency. This frees you from tying up invest-

ments and capital, as DIAB has full use of the equipment

continuously. DIAB has full capabilities and advanced

machinery to deliver any kind of shape.

Packaging and fitting sequenceThe packing is critical to ensuring you harvest the fullbenefits of using a kit. Gaining an understanding of your

lay-up flow enables us to pack and sequence the kit

parts to ensure that fitting the kit goes as fast as possible.

Further, in complicated kits we normally assist in the first

fitting to instruct your staff on how to reach the right result.

To get sequence right as well as kit improvements, ALWAYS

start laying up the kit from the same point in the mold.

Refinement and changesKitting is a continuous process, and the first prototype

normally requires some changes. For complex kits, this is

normally done on site when we attend the first fitting. We

then adjust and optimize the kit design prior to subse-

quent deliveries. Taking the time to go through needs and

requirements as outlined above significantly decreases

the amount of changes needed, saving time and money.

Packing and fitting

sequence

Kit design:

Finishing selection, nesting

and optimization of kit

Structural design

and core selection

Composite

manufacturing processKit manufacturing

To ensure optimal lay-up

sequence and ability to

optimize the kit, always start

laying up the kit at the same

position in the mold.

!

Select the optimal finishingGet a competitive edge

Download the DIAB FinishingGuide at diabgroup.com

Sandwich composites andcore materials. How they workand why you should use them.

For more information, downloadthe DIAB Core Guide at

diabgroup.com



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Customer kit request Initial meeting Kit design proposal Costing Prototype kitFinal

production kit

Changes

Customer kit requestFor customers, there are a number of factors to take into

account when making a kit request that will considerably

speed up the development process.

We recommend you spend some time thinking about

the key success factors for your application, as described

earlier.

Specify the thicknesses and core properties required.

Ideally, you will provide a core drawing, or mold offset

for cores, bevel placement and angles. If this is not

possible, we can assist you.

If computer models are available, we need them in any

of the following formats. A 3D model and detailed 2D

drawings, along with notes, are usually enough tosolve the project directly at the kit department. 3D files

are normally exported as igs, stp, 3dm, sldprt, x_t. For

easier projects, pdf drawings are acceptable. With high

complexity, we prefer 2D files in dwg or dxf (vectorized

information).

Kit start-up meetingIn the start-up meeting, we discuss all the factors

impacting the design and manufacturing of the kit (see

the previous sections) so it is important that you have a

good understanding of your kit influencing factors prior to

this meeting. At this time, it is also good to have a look at

your manufacturing facility and go through the fitting flow of

core materials you normally use. We will make a detailed

run-through of all your requirements as they apply to the

kit solution we will propose, including:

Finishing selection

Tolerances

Proposals for structural design, if needed

Process selection and set up

Lay-up scheme, including preferred starting point

Packing instructions

Number of test kits

Number of kits per delivery

Other requirements

Design proposal and cost estimationAfter the start-up meeting, DIAB will make the kit design

proposal. Based on the design proposal, we will offer a

quote for the kit. If this is satisfactory, DIAB will produce

a prototype kit for delivery. In the design proposal, it is

critical to review that:

Cored areas are correctly placed in relation to areas

with single skin:

- Distances from core to mold edges are correct

- Thickness and density transitions are correct

Core edges are correct (bevels, radii, etc.)

Kit prototypeDepending on the complexity of the prototype kit, a

representative from DIAB will be present when it is fitted to

identify potential improvements or corrections. After this,

we will make alterations to the design. If the first steps of

the process have been focused and detailed, there are

normally relatively few corrections required, increasing the

speed of delivery as well as keeping cost down.

Final kit design and series productionAfter making the corrections, we start serial production of

the kit. In most cases, once application production moves

on, we continuously make changes to fine-tune the kit as

well as the customers manufacturing process.

The DIAB kit process

teaming with you for successKits can be complex. There is a lot of information that has to be right and the necessity for speed is high.

For this reason, DIAB works according to a predefined process in order to:

Reach high customer satisfaction in terms of kit performance, ensuring that all aspects of the kit are covered

Keep the lead time from kit request to prototype to full-scale manufacturing as short as possible

Below, we outline the kit process and what is critical in each step:



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Optimized

kit

Customer

DIAB

ccg-composites.com

Optimization

through the right competenceCompetence and experience in sandwich technology, cores, finishing and processes are key in designing kits

according to customer-specific needs. DIAB has extensive hands-on as well as theoretical experience in kits

and sandwich technology. We feel equally at home with the CAD program as we do setting up infusion

processes and fitting kits i nto the mold.

DIAB kitting expertsThe DIAB Kit Departm ent is an integr al part of the kit

process and heavily involved from the initial stage to

series production. DIAB has kit operations and strategic

partners located in the Americas, Europe and Asia. They

are experts in cutting complex shapes in both 2D and 3D.

One of the most valuable aspects of working with DIAB

is the nesting and optimization of the kit. The kit department

makes sure the surface of every sheet that becomes part

of a kit is utilized to its maximum and that the design fits

into your operations critical to optimizing the kits value

for you as the customer.

DIAB Technical Services is our competence hub, encom-

passing everything you need to know about sandwich

designs and kits. They step in to work with more complex

kits and can optimize structural design, finishing and kit

design based on customer needs. Technical Services

works closely with your designers and manufacturing

staff to capture your needs and requirements.

Composites Consulting Group (CCG) is an independent

consulting company for composites (wholly owned by

DIAB), and can assist you with pure consulting work in all

aspects of sandwich composite design and manufacturing.

To make the kit process as efficient as possible, your

DIAB account manager leads the project together

with you. A highly experienced team of kit experts

supports the account manager, ensuring your kits are

optimized according to your needs with exactly the right

competence to fit the complexity of your application.



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diabgroup.com

DIAB Group

Box 201

SE-312 22 Laholm, Sweden

Phone: +46 (0)430 163 00

Fax: +46 (0)430 163 96

E-mail: [email protected]

www.pyramid.se

December2014

Core materials |Knowledge |Kits |Processing |Engineering |Training |Global presence local service

Making you more

competitive

DIAB is a world-leading supplier of sandwich composite

solutions that make our customers products stronger,

lighter and more competitive. Our extensive experience

in providing sandwich composite solutions to customershas made DIAB a leading partner in the sandwich

composite industry. DIABs solutions combine

high-performance core materials, value-added kits,

engineering and process services.

DIAB, Divinycell, Matrix and ProBalsa are registered trademarks

in countries all over the world.

DIAB Divinycell Kits Guide - DIAB Knowledge Series

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