NEW DuFLEX Website
ATL Composites is pleased to announce the launch of the new updated website specifically dedicated to DuFLEX Composite Panels. The site includes information on the panel options available in the range, basic applications techniques, down-loadable data sheets and projects.
DuFLEX Composite Panels were developed by ATL in the early 1990’s to reduce construction time and optimize structural weight in the production of lightweight composite structures. Time consuming laminating, coring and vacuum bagging steps normally required to fabricate high performance composites are avoided, and material waste, labour and tooling costs are greatly reduced. Over the years, DuFLEX has become widely accepted in the marine industry, and hundreds of projects have incorporated the system, both in Australia and Internationally.
In more recent years, lightweight DuFLEX panels have been incorporated into architectural and transportation applications where is also a demand for lighter, stronger, stiffer, more durable structures. Complex forms can be created relatively easily, broadening design freedom and offering rapid processing and construction to significantly lower fabrication costs.
Standard DuFLEX panels are 1200mm x 2400mm cored with rigid end-grain balsa or structural foam cores, and laminated with a high-performance epoxy resin reinforced with multiaxial E-fibreglass or carbon fibre skins. Fibre orientation and ply schedules are based on design or engineering specifications to best meet weight targets, stress and impact loads, and other design parameters.
Our product range is continually assessed and revised, and in addition to the Standard Panel range and CNC Routed Kits, new value-added services are now available to expand the advantages of using the DuFLEX System. High Density Inserts and Full Size Component Packs can now be supplied to reduce build times for fabricators working to tight build times.
ATL Composites is ISO 90001:2015 certified and our production facility and techniques have been audited by International Certification Group DNV-GL and have been issued with Shop Approval # KBZ 1095 for The Production of Composite Panels. DuFLEX Panels are manufactured in a controlled environment and under-go strict Quality Inspections at all stages during the manufacturing process to ensure customers consistently receive high quality products and services.
DuFLEX Composite Panels Saved Time and Weight
In terms of quality and innovation the new flagship of the shipping company Luzern (SGV) MS 2017 sets a new milestone in Swiss shipping.
March 21st 2017
In autumn 2013, the Board of Directors of the SGV decided on construction of the new, large passenger ship with space for 1,000 passengers.
The well-known yachting design office Judel / Vrolijk & Co from Bremerhaven were commissioned to do the design, and the planning and construction is being carried out by Shiptec AG, one of the largest shipyards in Switzerland.
A new sundeck floor was specified for the upper section of the vessel and vdL Composites GmbH were approached to supply a composite alternative to provide strength, stiffness and durability. DuFLEX Composite Panels were specified as the best option for the large 275m2 area.
DuFLEX – Optimised Kit Technology – 109 Custom DuFLEX panels ranging from 1.3m to 2.4m in length were manufactured at the vdL Composites facility in Wesel, Germany. The panels were cored with 60mm Divinycell H80 and reinforced with multiple layers of multiaxial E-fibreglass, laminated with a custom-blend, high performance epoxy resin. Divinycell H80 is widely used, and has a proven track record, in the marine industry for leisure, military and commercial applications. Combined with epoxy laminates, the DuFLEX H80 panels provide excellent mechanical properties at low weight, a consistent high quality finish, excellent chemical resistance, low water absorption and good thermal/acoustic insulation.
The panel edges were machined with the DuFLEX Z-Joint and CNC-routed from electronic design files, enabling the panels to be joined and the full-sized parts to be released. The panels were delivered, along with the proprietary DuFLEX Z-Press, to Shiptec to be joined and fitted on site. The Z-Press was set-up on the deck of the vessel, and vdL staff were present to assist with joining and to offer technical support during the process.
On installation, the full-sized parts fitted perfectly into the specified areas eliminating the need for time- consuming trimming and fitting. The large sections were lifted into position with a vacuum lifter and Pro-Set Epoxy adhesive was used to fill and bond non-scarffed edges. Multiaxial E-fibreglass tapes were applied to complete the structural requirements on those joins.
A driving factor in the choice of materials for this project was the installation time-frame. DuFLEX offered the perfect solution to meet a tight deadline for project completion.
The first contact was made to vdL on February 2 2016, with the first delivery on March 11. The first panels were joined on March 21 and 3 days later, one third of the deck was joined and mounted on the steel frame. 166 parts were installed to complete the 275m2 deck. Compared to conventional methods of hand-lamination, this saved hours in labour, wastage and tooling costs.
MS 2017’s maiden voyage is scheduled for May 2017. The ship will be officially named at this time and will be scheduled for trips on the Lucerne-Flüelen-Luzern and Lake Lucerne.
Sanctuary Cove International Boat Show 2018
ATL Composites will be exhibiting at Booth #314 IN THE SUPERYACHT & MARINE PAVILION at this year’s Sanctuary Cove International Boat Show from Thursday May 24th thru Sunday May 27th.
“We are really looking forward to this year’s 30th Anniversary Show,” says Lorraine Murray, Director at ATL. “As a leading supplier of advanced composite materials and engineering to the marine industry for 38 years, we continue to look for ways to improve our products and services, and enjoy the opportunity to discuss and suggest solutions for specific projects with customers at the show.”
This year ATL will be displaying products specifically developed for the Marine Industry including the Six10 Structural Adhesive from the internationally recognised WEST SYSTEM epoxy range and DIAB’s Divinycell Structural Cores which have a proven industry history and are the choice for naval architects and manufacturers worldwide.
We are also show-casing two outstanding projects that were built with our DuFLEX and Featherlight composite panels – Kato the G-Force 2000 Speciale and Barcoo Drift, the 14m Roger Hill Power Catamaran.
Please visit our stand to meet our experienced Technical Team and to discuss how our products can work for you.