Benson Guo‘s impactful Industrial placement.
Chippenham, England – Carbon ThreeSixty (CTS), a leading high value manufacturer specialising in advanced composite products, is making significant strides in the aerospace, automotive, and defence sectors. At the heart of this innovation is its vibrant Research and Development team, where cutting-edge projects are brought to life.
Benson Guo, who recently completed a Year-in-Industry placement within Carbon ThreeSixty, offers an insightful look into the dynamic work being undertaken. Under the guidance of Andy Smith, Chief Strategy Officer and Head of R&D, Benson delved into a diverse range of projects, gaining invaluable experience and contributing to several key initiatives.
Cultivating Expertise: A Focus on Growth
Benson’s journey at CTS began with foundation training, including a four-day professional development course ‘Composite Strength and Stiffness.’ This not only developed his early-stage understanding of Classical Laminate Theory (CLT) but also provided crucial insights into its practical application in composite design. Hands-on experie
nce followed with training on Resin Transfer Moulding (RTM), involving the rigorous process of producing material qualification composite panels.
“Much of the learning was encouraged and expected to be independently carried out, but help was never far away when needed,” Benson noted, highlighting the supportive learning environment at CTS. This ethos extended to mastering SolidWorks, the company’s preferred CAD software, and various other topics as new projects emerged.
Driving Innovation: Key Projects and Breakthroughs
Benson’s involvement spanned several high-impact projects, showcasing CTS’s commitment to pushing the boundaries of composite technology:
- Hi-Den2: Advancing Hydrogen Storage Benson joined the Hi-Den2 project team. HiDen2 wasan NVN-funded program focused on developing a Type IV, conformable, array-architecture, high-pressure hydrogen storage system.
- Automating Production: The Filament Winding Cell A significant in-house project involved upscaling and automating a 6-axis robot for filament winding. Benson was instrumental in consolidating the Bill of Materials for the robot end effector and, more notably, coding the tensioning system for the fibre feed spools.
- Mastering 3D Printing Technologies Benson took charge of setting up and managing a pair of Stereolithography (SLA) 3D Printers for prototyping parts, gaining valuable experience in safety procedures, lean manufacturing, and resource allocation.
- REACH: Solutions for Nuclear Environments In the REACH project, which aimed to deliver a composite solution for accessing hazardous waste storage, Benson aided in the extensive product testing and validation process.
- Lightweight Seat Coupons: Aerospace Material Analysis Benson was involved in overcoming challenges related to molding and pressing materials with varying thicknesses, learning to balance theoretical accuracy with practical feasibility in manufacturing.
- Pressure Regulation: Enhancing RTM Manufacturing Benson gained a valuable introduction to industrial control systems through the pressure regulation project,
- High Speed Rotor Overbanding: Iterative Design for Complex Geometries Benson designed a filament winding tool for overbanding a polymer propulsion fan.
- Tailored Fibre Placement: Benson received training on the Tailored Fibre Placement (TFP) machine and software. This rare opportunity allowed him to contribute to the development of this nascent technology.
Beyond Projects: A Holistic Learning Experience
Benson also contributed to various supporting roles, including Differential Scanning Calorimetry for quality control and Siemens SIMATICS PLC troubleshooting.
His placement at CTS provided profound insights into the advanced engineering industry, particularly the workings of a structural composites company focussed on series manufacture. He gained a comprehensive understanding of how research projects are selected, managed, resourced, and delivered within the framework of government funding schemes and industry collaborations.
“I enjoyed the independence and thus, the amount of responsibility the company entrusted me from early on in the placement,” Benson reflected. This fostered essential skills in time management, workload balancing, prioritisation, and initiative-taking.
His understanding of composite design and manufacturing significantly expanded, far exceeding his academic course modules. He gained first hand experience with the complexities of applying first-principles composite theory and witnessed advanced practices like Tailored Fibre Placement, which broadened his perception of composite capabilities.
Beyond the technical learning, Benson also appreciated the social aspect of his placement. “The environment at CTS itself has been welcomingl, with plenty of support and advice from senior members of staff whenever needed; and leniency for mistakes to be learning opportunities!”
Benson’s experience at Carbon Threesixty exemplifies the company’s commitment to fostering talent and driving innovation in the advanced composite materials sector, contributing to a brighter, more efficient future across multiple industries.
