The Society for the Advancement of Material and Process Engineering (SAMPE) welcomed nearly 4,300 participants during the four-day run of its 2006 Symposium & Exhibition, held April 30-May 4 at the Long Beach Convention Center in Long Beach, Calif. Billed as the premier materials and processing (M&P) industry event, SAMPE 2006 drew delegates from 48 U.S. states and the District of Columbia as well as 33 other countries.

Visitors had the opportunity to attend 12 tutorials and 250 papers and tour exhibits assembled by 230 exhibitors, including a large number of first timers. According to SAMPE, exhibitors were particularly pleased with the traffic on the show floor and, in common with exhibitors at the earlier JEC Composites Show in Paris (see p. 26), were generally upbeat. "We are very, very pleased with the responses we have received from our attendees, speakers and exhibitors," says SAMPE International past president Dr. Tia Benson Tolle, a structural materials branch chief for the Air Force Research Lab (Wright Patterson AFB, Ohio).

SAMPE also confirmed that its 2007 Symposium will be sponsored by SAMPE's Baltimore/Washington Chapter and will be held at the Baltimore Convention Center, in Baltimore, Md. The conference dates are June 3-7, 2007 while the exhibition dates are June 5-7, 2007.

On the show floor

For those who couldn't make it to the show, HPC staffers canvassed exhibitors and identified the following notable developments. HPC's feature articles on tooling and lightning strike protection (pp. 38 and 46, respectively) showcase additional products premiered at SAMPE.

Accudyne Systems Inc. (Newark, Del.) showed its the Conformable Compaction System (CCS) automated contour tape layer. Developed under NASA SBIR Phase I and Phase II programs, this latest-generation thermo- plastic prepreg tape/tow placement head features individual "fingers" that conform to local contours to apply compacting pressure and heat to material as it is layed down, for out-of- autoclave manufacture of 3-D parts. accudyne.gocomp.biz/2

Advanced Ceramics Research Inc.'s (Tucson, Ariz.) new, lightweight 30 lb/ft3, seamless ceramic tooling board will be commercially available in the latter half of 2006. It features a coefficient of thermal expansion (CTE) of 10 x 10-6 inch/inch/°F for environments up to 218°C (425°F). While current versions offer flexural strength of 3,000 psi/20.68 MPa and compressive strength of 4,000 psi/27.58 MPa, the company expects the commercial version to double these values. acrtucson.gocomp.biz/10

Advanced Composites Inc. (Salt Lake City, Utah) touted a continuous filament-wound molding compound, designed for joining filament wound structures and discussed the company's move to a new location in Salt Lake City, to improved production floor flow. advancedcomposites.gocomp.biz/2

AlphaSTAR Corp. (Long Beach, Calif.), a simulation software developer, has updated its Genoa analysis software to encompass different types of composite construction, including 3-D structures and ceramic and polymer matrix composites. Genoa can be used for progressive failure analysis through virtual testing on FEM models during the design phase or on actual parts as built. alphastarcorp.gocomp.biz/6

American GFM (Chesapeake, Va.) showcased two ultrasonic cutters: Model US-120 reportedly offers the highest cutting speed in the industry, providing high accelerations and decelerations (up to 20 ft/sec) with a maximum cutting speed of 4,800 inches/min (120m/min). It features linear and torque motors, has a profiling accuracy of 0.006 inch/0.15 mm and is designed for aerospace composites, technical textiles and other materials. Also on display: Model US20 uses a standard ultrasonic generator, convertor and sonotrode with a specially developed blade that cycles at 20,000 strokes/sec. agfm.gocomp.biz/8

Apex Machine Tool Co. (Farmington, Conn.) reiterated its expertise in producing metal tools for resin transfer molding (RTM), autoclave and compression molding processes. The company, whose core competency is high-precision machining, also produces trim tools, jigs and machining fixtures for the composites industry. apexmachinetool.gocomp.biz/1

On display at the Autometrix Precision Cutting Systems Inc. (Grass Valley, Calif.) booth, was the company's newest cutting machine for composite materials, featuring faster operating speeds and a more competitive price, according to the company. The modular cutting system, which incorporates composite components in its cutting head and crossbeam, can be customized to accommodate table sizes as large as 80 ft/24.4m long by 120 inches/305 cm wide. autometrix.gocomp.biz/3

At the Applied Sciences booth, Nanosperse Inc. (Martinez, Calif.) introduced commercially available nano-enhanced conductive resins and two-part adhesives developed under an exclusive license from the U.S. Air Force Research Laboratory and the University of Dayton Research Institute. The resins and adhesives contain the company's vapor-grown carbon nanofibers (CNFs). The latter also are available dispersed in resin concentrates, enabling users to custom-modify conventional resins, prepregs, coating and molding compounds. Designed to increase thermal and electrical conductivity, the CNFs also enhance strength, fatigue resistance and other physical properties. nanosperse.gocomp.biz/2

Bondline Products Inc. (Norwalk, Calif.) displayed its silicone-based technology for inflatable bladders used in bladder molding of complex hollow parts, including helicopter blades, spars for unmanned aerial vehicle wings other highly-loaded aerospace parts. Based on the company's RVBS (Reusable Vacuum Bagging Systems) silicone technology, the bladders provide multi-use, removable mandrels that apply interior consolidation pressure for hollow composite parts produced in closed molds. bondlineproducts.gocomp.biz/1

CMS North America Inc. (Caledonia, Mich.) demonstrated the fully-enclosed ARES 5-axis CNC machining center from parent company CMS SpA (Zogno, Italy). With over 4,000 machines installed worldwide, CMS specializes in cutting/machining of composites and lightweight, nonferrous metals and materials. cmsna.gocomp.biz/7

Coastal Enterprise Co. (Orange, Calif.) showcased new PB Fast Set one-part urethane adhesive, which can be fully cured in 30 minutes. It reportedly works well with both indoor and outdoor applications. Also on display were the company's PBLT and PBHT tooling boards. PBLT is designed for tooling processed at temperatures as high as 93°C/200°F, while PBHT is intended for applications at higher temperatures (to 149°C/300°F). Both products process without outgassing or otherwise affecting prepreg resin or adhesive cure. precisionboard.gocomp.biz/42

Dangar Engineering & Mfg. Inc. (Newbury Park, Calif.) announced the startup of Ukraine Fiberlite Products Ltd., the company's new manufacturing arm in Eastern Europe. Dangar president Dan Woods says move was made in an effort to cut labor cost in CNC-manufacturing of tooling, prototypes and molding of finished products for customers worldwide. dangar.gocomp.biz/1

DIAB Inc. (DeSoto, Texas) showed its "significantly reformulated" Divinycell HT high-temperature PVC polymer foam core, which features improved fire, smoke and toxicity (FST) properties. Qualified for aircraft interiors and other structural and nonstructural applications, the foam is nonhygroscopic, has less effect on the environment, has superior damage/impact performance and improved dielectric properties, says the company. DIAB also promoted its Core College courses for designers, engineers and others involved in composite construction, offering access to the latest developments in sandwich core materials and technology. The next class will be held Sept. 6 in Dartmouth, Nova Scotia, Canada. diabgroup.gocomp.biz/23

Eastman Machine Co. (Buffalo, N.Y.) showcased its new Eagle automated cutting and routing machine. The robust Eagle, with a heavy duty welded structure, high-pressure/high-flow vacuum table and steel-top plenum, is designed to handle thick (up to 1.375 inch/35 mm) and fairly dense materials, including cured composites and plastics. eastmancuts.gocomp.biz/30

Emerson & Cuming, part of Trelleborg Emerson & Cuming Inc. (Stavanger, Norway), exhibited its trademarked Eccospheres, hollow glass microspheres ranging in diameter from 20µ to 200µ. The syntactic filler reduces part weight, increases resin compressive strength and can be used in a variety of applications, such as thermal insulation and buoyancy for offshore composite structures. emerson.gocomp.biz/2

EDO Fiber Innovations Corp. (Walpole. Mass.) displayed a gearbox housing developed with EDO Corp. for Sikorsky's now defunct Comanche helicopter. The display illustrated the use of braid and other reinforcements in complex combinations to create a part that also includes strategically placed, comolded metal inserts. fiberinnovations.gocomp.biz/6

FireSafe Innovations (Rochester, N.Y.) exhibited PyroFend, its lightweight, fire-resistant material that can be cast to any shape or form. When cast, the material can be cut easily with a bandsaw or other cutting equipment. Reportedly easy to handle, the material is one-eighth the weight of concrete and does not give off toxic fumes during a fire. When exposed to flame, the product maintains its strength and form with minimal degradaton or shrinkage. The latter prevents fire penetration through cracks or corners. firesafeinnovations.gocomp.biz/2

Gerber Technology (Tolland, Conn.) introduced an updated version of its trademarked CutWorks software for its GERBERcutter ply cutting solution for composites manufacturers. A complete design, nesting and cutting package, the software can import/export files using multiple formats. The program's Base Module does all the basic cutting and kitting prep, while optional upgrades increase efficiency and cut costs. ToolPath optimizes piece placement to speed cutting time while its Nesting module maximizes material use. gerbertech.gocomp.biz/18

Hitco Carbon Composites Inc. (Gardena, Calif.) demonstrated its expertise in composite structures, rocket nozzles and high-temperature solutions with various part displays at its booth. The company called attention to its recent reception of Boeing's Silver Eagle Award for 2005 on the basis of its contribution to supply chain improvements for the C-17 Tailcone Program. hitco.gocomp.biz/15

Huntsman Advanced Materials (The Woodlands, Texas) showed a wide array of its composites products, including two new halogen-free laminating resins targeted to the printed circuit board (PCB) industry. AZYRAL one- and two-component epoxies comply with the most recent regulatory requirements for PCBs and offer low dielectric constant along with high temperature resistance and low coefficient of thermal expansion. The material is also a good candidate for bipolar plates used in fuel cells, says the company. huntsmanadv.gocomp.biz/11

Laser Technology Inc. (Norristown, Pa.) displayed its new Model LTI-6200S Shearography Inspection System, a compact, portable laser device for nondestructive inspection of aircraft. Commercially released shortly after the SAMPE show, the small, low-cost unit measures voids and porosity in repairs, identifies and locates impact damage and delaminations in solid laminates and reveals disbonds in sandwich panels. The device can be vacuum-attached to aircraft in any orientation, the company says, and it features a patent- pending cantilevered design to inspect edges and corners. laserndt.gocomp.biz/2

Lectra (Marietta, Ga.) touted its ProspinTechTexST, a new single-ply cutting solution that accommodates several cut lengths simultaneously, increasing production rates for small and medium diversified production runs, the company reports. The cutter can use a vibrating blade, punch or pen, and it is compatible with Lectra's full suite of software solutions. lectra.gocomp.biz/9

Lewcott Corp. (Millbury, Mass.) highlighted its resin systems: LC-194, an advanced phenolic system, is self-adhesive to aramid honeycomb and meets the flammability requirements for use in aircraft interiors. For sandwich constructions, EP255 toughened epoxy is self-adhesive to aramid and aluminum honeycomb, is fire retardant and cures in the temperature range of 235°F to 275°F (113°C to 135°C). EP254, for table-rolling applications, is a toughened 250°F/121°C curing epoxy available with several tack and drape characteristics. lewcott.gocomp.biz/7

LPT Corp. (Londonderry, N.H.) was joined in its booth by exclusive integration partner Verisurf (Anaheim, Calif.), a high-speed laser metrology company, with which LPT has recently formalized a partnership. LPT presented LPT10, a targetless laser projector that can be driven by nearly any CAD model, the company reports. Designed for rugged environments, the sealed unit has an advanced thermal management system that stabilizes operating temperatures. lpt.gocomp.biz/13, verisurf.gocomp.biz/1

Lucas Industries (Springfield, Vt.) is a long-time custom composite tooling fabricator, specializing in tool families and capable of high-precision machining and processing, supported by in-house CATIA, PRO-ENGINEER and SURFCAM software. Its display featured its highly accurate, vacuum integral metal tools for composites. lucasindustries.gocomp.biz/4

McLube Div. of McGee Industries Inc. (Aston, Pa.) presented MAC-860, a new water-based semipermanent release coating, formulated for extra slip to accommodate tools with deep draws and undercuts as well as small sprue openings. Stable to 480°C (900°F), the product is recommended for high-temperature applications. Also new: MAC-738 is a solvent-based semipermanent release coating that provides high gloss and superior part appearance, the company maintains. mclube.gocomp.biz/7

Meridian Automotive Systems Inc. (Allen Park, Mich.), at the SAMPE show for the first time, showcased its improved, powder-primable sheet molding compound (SMC), formulated with collaborators AOC Resins (Collierville, Tenn.) and Red Spot Paint and Varnish Co. (Evansville, Ind.). A new low-profile additive combined with improved resin formulation and coupled with a new primer allows powder priming and high-temperature painting of SMC, without sacrificing Class A surface finish. Meridian hopes for aerospace applications of the new technology. meridianautosystems.gocomp.biz/4, aoc-resins.gocomp.biz/24, redspot.gocomp.biz/3

Nelcote Inc. (Waterbury, Conn.), formerly FiberCote Industries, announced its change of company name and its intention to market its advanced composite products under the Nelcote trademark. The change is intended, says parent company Park Electrochemical Corp., to underscore the unification of Park's various products lines under similar Nelco, Neltec and now, Nelcote trade names, a reflection of Park's commitment to commit the resources of the Park organization to development of Nelcote's advanced materials business. nelcote.gocomp.biz/3

Nida-Core Corp. (Port St. Lucie, Fla.) displayed closed molding products geared to "the reluctant open molder." Nida-Fusion STO or STF (for flexible foam) is a closed-cell Structiso polyurethane foam with fiberglass fabric skins, which is stitched through the foam thickness with additional glass roving. During resin infusion, the resin follows the stitches and, when cured, forms a truss-like through-thickness reinforcement. Also on offer: Nidaflow resin infusion flow medium, a nonwoven polypropylene stitch-bonded between two layers of binder-free chopped fiberglass. The highly conformable needled material improves resin flow. nida-core.gocomp.biz/42

Norplex-Micarta's (Postville, Iowa) new products included trademarked BRASS, reportedly the only commercially available Class 1-A fire-rated, projectile-resistant but easy-to-machine fiberglass laminate for bullet-resistant architectural and building projects. Also new: NP613 high-performance thermoset composite material, which is used to separate and isolate electrical contacts (to prevent arcing) and provide structural strength in transformer applications. norplex-micarta.gocomp.biz/11

Olympus Micro-Imaging (Orangeburg, N.Y.) presented its LEXT Confocal Laser Scanning Microscope. It offers 0.12-micron resolution and accurate 3-D measurement capability, the company reports, with magnification power from 120x to 14,400x. olympusmicroimaging.gocomp.biz/1

Olympus NDT (Waltham, Mass.) supplies a wide variety of nondestructive testing equipment, including Panametrics, R/D Tech and NDT Engineering brands. One of the new items at the show was the company's OmniScan MX, a modular, portable instrument that incorporates phased array, eddy current array and conventional ultrasound capabilities for composite part testing. Color images in real time can be exported for reports, and a mouse and keyboard can be attached, if desired. The compact unit's rugged case reportedly can withstands abuse and harsh conditions. panametric-ndt.gocomp.biz/3

Reliant Machinery Ltd. (Philadelphia, Pa.) detailed a new design for its Coolstream Laminating System. The new configuration includes an available 2,700-mm/106-inch tunnel capable of heating capacity along its entire length or, alternatively, 1,700 mm/67 inches of heating and 1,000 mm/40 inches of internal cooling capacity. Options include increased kilowatt capacity and various operating widths, ranging from 600 mm to 1,800 mm (24 inches to 71 inches), permitting the user to configure the system to suit the application. The system also features a gap-opening system (GOS) that permits materials up to 30 mm/1.2 inch thick to be processed. reliant.gocomp.biz/3

Richmond Aircraft Products Inc. (Norwalk, Calif.) touted its Vac Pak 400Y multilayered vacuum bag film, available in widths up to 12m/39.3 ft. The company maintains that the film, designed for low-temperature applications (maximum 150°C/300°F), is typically more economical than standard nylon bagging film. richmondaircraft.gocomp.biz/13

Rohm America LLC (Piscataway, N.J.) has established FEM modeling services to assist companies that want to optimize their structural performance by incorporating ROHACELL structural foam into their stiffeners. In this regard, Rohm's Alexander Roth presented a paper entitled "Numerical Analysis of Hollow and Foam-filled A-stringers," which detailed the mechanical/structural benefits gained by using ROHACELL as the primary core or mandrel in a composite sandwich stiffener. rohacell.gocomp.biz/27

SAERTEX USA LLC (Huntersville, N.C.) highlighted its tackified SAERFIX reinforcements, which have a special bonding agent that creates a self-adhesive effect, eliminating adhesive spray-up steps, especially in large molds. Also, the company's Vacuum Assisted Process (VAP) infusion method reportedly shortens processing time yet improves infusion quality via a permeable membrane that creates a resin barrier, but allows gas and air removal into an exterior vacuum chamber. saertex.gocomp.biz/11

Scion Industries split this year into two entities: Scion Core Systems (Loveland, Colo.) continues as the North American distributor for Degussa/Rohm Rohacell products, providing core as sheets and CNC-shaped parts for aerospace customers. Loveland-based Scion Aviation makes carbon, glass and aramid structures for manned and unmanned development aircraft, sport jets, and flight simulators for the likes of Boeing and General Dynamics. scionindustries.gocomp.biz/6

SL-Laser Systems LP (Charlotte, N.C.) presented the ProCollector Mobile Laser Coordinate Measurement Machine, which offers noncontact, fully automated measurement and collection of ply coordinates, enabling reverse engineering and other similar processes. The mobile unit weighs under 6 kg/13.2 lb. Also new: The ProDetector Laser Vision System, a laser projection system that features targetless calibration and built-in visual verification of ply alignment. sl-laser.gocomp.biz/9

The Boeing Co. (St. Louis, Mo.) introduced its MAUS V nondestructive testing/inspection system, a portable C-scan ultrasonic technology that integrates traditional and nontraditional techniques into a single package. Features include two new sensor options: The Flaw Inspecta phased array option joins traditional pulse-echo, through-transmission and shear-wave ultrasonic methods. The Trescan transient eddy current option has been added to standard single- and dual- frequency eddy current methods. In bond test mode, the unit offers resonance, pitch/catch and mechanical- impedance methods. boeing.gocomp.biz/13

Virtek Aerospace (Waterloo, Ontario, Canada) announced its reception of a $2 million (USD) Airbus Industrie (Toulouse, France) contract for Virtek's iLS (Intelligent Laser Systems) mobile laser projection units for use in manufacturing Airbus' A400M military transport. The projection systems measures and locates adhesive fasteners throughout the aircraft wing so pneumatic and fuel systems can be accurately fixed to airframe substructures. virtek.gocomp.biz/13

In its first SAMPE showing in seven years, Wausau Paper (Rhinelander, Wis.) offered a release liner for use in prepreg tape manufacturing processes, both as a process liner and carrier liner. The company's one-side and two-side coated liners are used in automotive, recreational, construction, marine, energy and aerospace applications. wausau.gocomp.biz/1

Zund America Inc. (Franklin, Wis.) demonstrated its precision composite material cutter, with motor-driven head. The company sells 700 units or more per year and has a large selection of machine sizes and tools and can customize machines to customer specs. zund.gocomp.biz/1

Zyvax (Boca Raton, Fla.) reported that Airbus Industrie recently approved its mold release products for use on its aircraft, completing approval processes that have included aircraft manufacturers Boeing, Lockheed, Cessna and Bombardier. The company recently released Waterworks Fresh Start, a solvent-free, nonflammable, odorless tool stripper/cleaner that contains no VOCs or HAPs. zyvax.gocomp.biz/12