From Gales to Sails
When it comes to manufacturing large parts for wind turbines or aircraft, composite moulding processes are the norm. But did you know that the vacuum bagging composite moulding process is also a key technology used in producing marine vessels today, despite the predominance of steel? As an alternative to and in combination with traditional steel structures, composite parts are used in various marine applications such as boat hulls, luxury yachts, decks, and superstructures.
However, for these parts to be able to demonstrate their advantages in the best possible way, small parts are needed in relation to the finished structure: tapes. In this article, we will take a closer look at how these highly specialised helpers can significantly improve the manufacturing process and what advantages this offers for manufacturers and end customers. All on deck, let’s set sail for new waters where adhesive tapes make waves!
One reason for building ships, especially large ones, with steel is usually driven by costs. In general, composite moulding parts can be more expensive than steel structures, but they can offer several advantages that can justify the higher cost.
For example, composite materials have a higher strength-to-weight ratio than steel, meaning that less material is required to achieve the same strength. This can result in weight savings, which is becoming more and more of a focus along with electrification, alternative propulsion technologies, and more sustainable and economical transport.
Composite moulded parts are on the rise to reduce fuel consumption, allow for more cargo capacity, and increase the speed and range of marine vessels.
But, there are other advantages — these parts are not prone to corrosion, which can significantly extend the lifespan of marine structures and reduce maintenance costs. Composite materials also offer greater design flexibility, allowing for more complex and efficient structures to be created.
Overall, while composite moulded parts may be more expensive than steel structures initially, the long-term benefits can outweigh the higher cost. Before we sail full steam ahead, let us set the course right in identifying how tapes can help to make manufacturing of composite moulding parts even better, save time and costs and create improved end results.
The manufacturing process with vacuum-assisted resin infusion is similar to most composite moulding processes for other large parts in wind energy or aviation. Although the moulds are usually large, small parts like special tapes offer significant advantages in various applications.
Mould Release Tapes, for example, provide a consistently superior release from the mould and easy demoulding part after part. These tapes, such as those from our Saint-Gobain® CHR® range, are typically made of materials like PTFE or polyimide to withstand high temperatures and pressures. They help achieve a defect-free surface, are conformable, temperature resistant, and ensure clean release with no residue. All of this while improving the manufacturing process throughout!
A major advantage of these industry-leading tapes is that their use can result in higher quality surfaces, less post-treatment, and reduced work in downstream processes like sanding, finishing, painting, etc. This helps manufacturers save time, effort, and costs. For the end user, on the other hand, reduced lead time and especially the excellent surface quality, which can result in reduced drag and improved fuel efficiency, can make all the difference. Additionally, if needed, tapes with a surface texture can be used to create a textured surface finish on the composite part.
Tool Protection and Seaming Tapes are used to join two or more composite parts together. These tapes are typically made of materials like extruded, high modulus, and skived PTFE or FEP, which are strong and durable. Our CHR products help create a superior release surface for composite materials and improve tool protection. Their clean release features leave no residue, help streamline production processes, and reduce post-treatment efforts.
CHR 2255 and 2250 can be used at the edges of moulds and to cover seams between release layers to give the Mould Release Tape a longer life. PTFE Film tapes such as 2045-3 offer a smoother surface and a thicker PTFE layer, which can provide a longer life compared to conventional tapes.
Flash Masking and Hold-Down Tapes are used to cover areas of the mould where excess resin may accumulate during the moulding process. These CHR Polyimide or PET tapes help to mask bond lines and remove flash. They are temperature resistant, and there are non-silicone options available. These tapes can be easily removed after the moulding process is complete.
Overall, special tapes for composite moulding offer significant advantages over liquid or gel solutions as they are less labour-intensive, prolong the lifetime of tools and moulds, and allow for superior surfaces with minimal post-treatment after the composite moulding process is complete.
After exploring the benefits of composite moulding technology in marine vessels and the advantages of using specialised tapes in the manufacturing process, it's clear that these technologies are changing the way marine parts are made.
To take advantage of these innovations like increased efficiency, protection and to achieve better results, it's important to work with your tape expert to find out which tapes are ideal to tape your marine parts for the better.