SUBCONTRACTING


due to the high value of parts, but also the most challenging regarding its quality and efficiency requirements. Proving itself to these markets as a new company will be


the next big step for Synergy, which it plans to achieve through the relentless pursuit of quality, be it through the extensive utilisation of MRP software from 123insight and material life management software from Jetcam or the strict adherence to Six Sigma and the quality systems learned through the two founders’ previous work. This has recently been proven through the company’s achievement of ISO9001 status in just three months, and it has now set its sights firmly on the aerospace AS9100 and automotive TS16949 standards.


Aiming high


Further aiding its acceptance will be the fact that Synergy has positioned itself with an ‘advanced composites’ focus, with the company aiming towards developing specific expertise in the use of prepregs and thermoplastics as well as new grades of E-glass and S-glass fibre products which will be important in the renewable sector. This is also demonstrated in the high standard of the equipment at its facility. Its clean room for example, adheres to the strict temperature and humidity controls required of the aerospace sector, and its autoclave is capable of an unusually high 450°C and 20 bar pressure, which will be important for processing some of the newer aerospace resins, thermoplastics and future experimental work. With this equipment, the long-term aim of the company is not


only to develop new materials, but also bring the cost of production down so that composites can be used as a viable alternative for traditionally metallic components further down the value chain. As such, the other major challenge for start-up composite manufacturers can simply be the level of expertise required for the establishment of efficient, repeatable processes, regarded by many as the so-called ‘black art’ of black metal production. When it comes to this aspect of the business however,


Ellel is keen to change peoples’ attitudes: “As far as I’m concerned there is no ‘black art’,” he describes. “We just don’t yet know what all the variables are and how they can best be controlled. Some people say ‘we always make a bad one now and then’, but to me that’s not acceptable. The throughput we’re seeing now compared to when we started production has already undergone a vast improvement. We’re at an 80-90% yield now but there’s no reason why we can’t attain ‘right first time’ procedures before too long. “At the moment we’re defining processes and creating a


baseline. Sometimes things that are often overlooked such as how long the material is in the bag before curing, the shelf life of the material or the temperatures pre-, during and post- processing can cause crucial variations in form. You have to look at everything. We also plan to run health checks every morning on our equipment.”


Great potential


Despite being near the beginning of the technology maturity curve with many aspects of production, Ellel believes that with the UK composite subcontracting industry in its infancy, there is great opportunity not only to align itself with major programmes but also to take the lead in research. While unable to talk about the specifics of current projects,


Ellel adds: It’s a very exciting time and we want to link up with the key research centres and OEMs and develop the supply


Synergy’s tightly temperature and humidity controlled clean room


Synergy’s initial investment has necessarily included a full range of inspection equipment


The dedicated lab facility, which is currently focused on Synergy’s Trelleborg contract


chain of the future. We’ve developed some processes and materials already and are assisting several companies in developing cost-effective out of autoclave and heated mould techniques for the renewable sector.” Although the future still contains many unknowns, what is


clear from visiting a company like Synergy, is that there are many different opportunities for those looking to get into the composites sector. The trick for new companies will be finding the right niche and processing know-how to instil confidence in their customers.


Ó www.synergycomposites.com Autumn 2010 | Composites in Manufacturing | 21


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