SUBCONTRACTING


Andrew Ellel and Lee Moffatt in front of Synergy’s high-spec autoclave


The new generation


For some time now, the manufacturing sector has been poised on the verge of a dramatic change as the economics of using composite materials in mainstream products fall into place, but what are the opportunities and challenges that subcontractors moving into the sector can expect? Simon Lott reports.


are still many unknowns as far as the actual development of the industry is concerned. In the UK, composite processing has so far remained on a niche scale, but the first shoots of a new industry are beginning to appear to support the anticipated demand. Lancashire-based Synergy Composites, situated close to


W


the UK’s North West aerospace cluster, is one of only a handful of subcontractors in the country focused solely on composite production. The company was established several years ago by two former BAE Systems engineers - operations director Lee Moffatt and sales and marketing director Andrew Ellel - after deciding there was a gap in the market and officially began trading as Synergy in June 2009. Since then the company has been completing phase one of its development plan, gearing up for production, attaining the necessary quality accreditations and has wasted little time in becoming involved in a variety of research programmes. It has also recently entered into a long- term contract to produce materials for the major Swedish manufacturer, Trelleborg AEM and is now seeking to add to its portfolio with more production work. Starting out in the sector has not been easy, but high as


hile the potential for new business opportunities generated by the expansion of the composites sector looks set to change the face of manufacturing, there


the risks are, so are the rewards and Ellel believes that while it is important for the sector’s growth that more companies like Synergy emerge to support the industry, the barriers can be particularly high. “A machine shop can be set-up with a single mill and after you’re doing so many hours work per day, you invest in another mill and grow organically,” he explains. “With composites that model doesn’t work. You can’t manufacture anything without a clean room, an autoclave, post-cure ovens and resin transfer equipment so you need to be prepared for a large capital investment and a lot of time and effort.” The company’s initial investment encompasses all of this


plant as well as an extensive suite of inspection equipment. Once the company is firmly established, phase two will add services such as 5-axis milling and painting, with the aim being to have the capability to produce finished components and subassemblies. Although he wants Synergy to be involved in every sector,


Ellel explains that he sees the greatest opportunities in the automotive sector, as much like aircraft such as the Boeing 787 have already done in the aerospace industry, the next generation of mass produced cars will see much greater use of composites, creating a step change in demand. Aerospace, which offers many opportunities as far as new materials and techniques are concerned, will also be particularly important


Autumn 2010 | Composites in Manufacturing | 19


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