iCOMAT
A revolutionary carbon fibre delivery system
Carbon fibre (CF) is lauded for its high tensile strength, low weight, and versatility. Consequently, it is prevalent throughout high-performance sectors including aerospace, automotive, and sporting goods. However, while strong, CF is expensive and difficult to sculpt into precise shapes – it can only be laid in straight lines and to sculpt more precise shapes, many strands of discontinuous tape must be laid in a series of rotating straight lines. This generates huge quantities of expensive CF waste and ultimately results in a product containing intrinsic focal weaknesses.
iCOMAT have developed Rapid Tow Shearing (RTS), a world-first, patented technology that can overcome these problems by laying CF tape in curved patterns. Using RTS, CF tape can be laid in complex geometric patterns, with no reduction in material resilience and dramatically reduced quantities of waste.
A need for rapid electronics development
After validating their technology, ICOMAT needed to showcase their RTS technology to key industry partners. This required a boost of electronics and control expertise to supplement their existing knowledge.
Specifically, iCOMAT required:
Methods to monitor and control the many parameters of the iCOMAT system, in real time.
An integrated electro-mechanical system, consolidating individual components.
Automated process control algorithms to reduce human intervention.
STL: innovation with tangible results
STL have over 200 years of combined expertise encompassing electronics, mechanical engineering, embedded software, and innovation. By applying structured development processes, detailed requirements capture, and systems control expertise, STL were able to deliver a tailored electro-mechanical system, built upon industry standard programmable logic controller (PLC) architectures, fulfilling the needs of iCOMAT.
This led to tangible benefits for iCOMAT: in less than 12 months, and with the support of STL, they were able to rapidly progress through the technology development pathway. Accelerated development has shortened their commercialisation journey and has allowed the iCOMAT team to confidently present their technology to established industry players.
The following features, were developed by STL and were fundamental for ICOMAT’s progression:
A master control system based on PLC architectures to enable flexible development, easy management of system parameters, and a streamlined, industry compliant route for future developments and upgrades.
The consolidation of 4 separate systems, including temperature and velocity control systems, into 1 automation-ready master control system.
A sophisticated sensor and I/O electronics configuration with low latency components to facilitate real-time monitoring and control.
Design, construction and implementation of new wiring and circuitry for new and pre-existing hardware.
A user interface providing granular controls for system management.
Automated control algorithms to reduce the time-cost of manual processes.
The iCOMAT RTS head unit
“STL supported iCOMAT in building a robust technology demonstrator that we’ll use to run performance analysis in partnership with leading OEMs in aerospace and automotive. STL supplemented iCOMAT’s mechanical engineering capability with electronics, software and control expertise, which was crucial at this early stage of the company's development. We look forward to working with STL again at the next stage of the technology development!”
Dr Evangelos Zympeloudis, (CEO, iCOMAT)
STL supported the scale-up of iCOMAT and helped them integrate advanced electronic control systems into their state-of-the-art offering. iCOMAT required a development programme that accelerated their technology from a proof-of-concept to a model suitable for industry demonstration and testing. STL were able to work closely with iCOMAT and deliver a system that adds tangible value to the iCOMAT offering .
At STL, we work with our clients to evaluate and apply opportunities that provide real business benefits. We aim to augment your skills, de-risking new tasks so you can focus on the core business activities. Drawing from both in-house knowledge as well as an extended network of specialist consultants, STL can avoid the pitfalls associated with bringing high-risk technologies to market and support the needs of our clients.
For more information on how automation and advanced systems can be applied within composite materials or other sectors, or to find out how STL can support the development of your technology in general, contact Peter Stirling (CEO, pstirling@stl-tech.co.uk).