This challenge is seeking an advanced simulation tool, capable of accurately predicting the ply by ply movement, deformation and defect generation/distribution in a composite laminate undergoing forming process at any stage in the process.
Sponsoring Department: National Research Council (NRC)
Funding Mechanism: Contract
Opening date: November 23, 2018
Closing date: January 14, 2019, 14:00 Eastern Standard Time
Please refer to the tender notice for this challenge on Buy and Sell
NRC Aerospace is doing research and development of composite material airframe structural elements and their productionisation, allowing Canadian composite manufacturers to form composite materials with optimal quality. But the lack of a simulation tool is a problem for NRC because its composite forming technology is only part of the solution for Canadian manufacturers. Current composite material manufacturing techniques are very empirical, involving time consuming and costly trials and errors. In presenting the forming technology to a new client for a specific application, the ultimate goal for the manufacturer is to shorten the adaptation stage by predicting and, consequently, avoiding possible defects that are commonly generated in forming processes. Industry's best practices are not reflected in any reliable and accurate simulation software.
The advanced simulation tool requested here will require the creation of mathematical models capable of simulating accurately the composite material forming process. With a reliable and accurate simulation capability in place, the Canadian composite manufacturers would be able to form composite materials with optimal quality, using their own or NRC's forming technology and increasing their competitiveness. This would mitigate risk and time/cost associated with the empirical methods used today.
Desired outcomes and Considerations
The solution to be provided in this Challenge by a small business must be a numerical simulation tool, featuring:
- A material library with populated properties to model the part behaviour during forming; with the capability to add new materials to the library.
- Capability to accurately model forming of flat thermosetting laminates into complex (double curvature) shapes, while taking into account transitional chemo-rheological changes in matrix and mechanical interaction of reinforcement.
- Capability to integrate ply movement and displacement data from non-destructive evaluation as a means for simulation tool calibration and process feedback.
- Capability of modelling resolution of common forming problems, such as:
- Predicting ply wrinkling (at least one layer waviness) due to forming of critical regions such as corners, folds, and joggles (which are steps formed by two adjacent reverse bends)
- Predicting laminate thickness changes (min to 5%) due to forming process of a part
- Predicting ply movement irregularities in laminates with stacks of multiple plies (1-50 layers) with similar orientation
- Capability to optimize the forming process based on selected forming process parameters (such as material properties, temperature, pressure, and forming rate)
- The software must be capable of predicting spring back and warpage of composite laminates based on a cure cycle, tool, material and geometry conditions after a cure.
The proposed solutions should:
- Offer a graphical user interface allowing for the generic forming modelling process and its adaptation to a client specific manufacturing process, such as NRC's forming technology.
- Be capable of optimizing a specific application and inform ideal process parameters to reduce costs while ensuring a high quality part.
Background and Context
The current industrial approach to tailoring a forming strategy is to conduct case-specific experimentation. In the current state of the art, manufacturers are confronted with the difficulty to produce rapid, repeatable and high-quality components; one of the most attractive approaches is by using advanced forming techniques. Here, a flat charge of material is first layered using automation. The flat charges are then formed into complex shapes, and the preferential deformation is promoted by targeted and controlled heat and force application. The material undergoes a phase of highly transient, rapid, and irreversible state, which has to be predicted and controlled with high fidelity. During this stage, it is critical to attain optimal ply orientation, while avoiding defects associated with mechanical manipulation of viscoelastic material. The chemo-rheological transformation of resin state affects reinforcing fibres, plies and laminate on micro and macro scales. One of the pertinent process-development challenges is that the underlying complex and competing ply movement mechanisms, which are governed by global deformation, are hidden. Currently, their relationships are implied from the end conditions. As a result, the accuracy of the existing chemo-rheological and physics-based simulation tools is difficult to ascertain.
Today, computer simulation is an essential part of any advanced manufacturing technology in order to improve designs and reduce development times and costs. However, most applications so far have focused on a general approach to composite fabrication as a single module of global simulation software. The literature lacks a targeted simulation tool specific to composite manufacturing. The industry needs commercial and viable simulation software which it can depend on for simulating different composite processes, particularly composite forming technology. These sorts of tools within commercial simulation software should be maintained, updated and advanced regularly. To our knowledge, no current commercial software is capable of addressing the forming process as explained in this challenge.
Maximum value and travel
Maximum contract value
Multiple contracts could result from this Challenge.
The maximum funding available for any Phase 1 Contract resulting from this Challenge is $150,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable, for up to 6 months.
The maximum funding available for any Phase 2 Contract resulting from this Challenge is $1,000,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable, for up to 2 years. Only eligible businesses that have completed Phase 1 could be considered for Phase 2.
This disclosure is made in good faith and does not commit Canada to contract for the total approximate funding.
For Phase 1 it is anticipated that two meetings will require the successful bidder(s) to travel to the location identified below:
Kick-off meeting: Montreal, Quebec
Final Review Meeting: Montreal, Quebec
All other communication can take place by telephone.
Solution proposals can only be submitted by a small business that meets all of the following criteria:
- for profit
- incorporated in Canada (federally or provincially)
- 499 or fewer full-time equivalent (FTE) employeesFootnote *
- research and development activities that take place in Canada
- 50% or more of its annual wages, salaries and fees are currently paid to employees and contractors who spend the majority of their time working in CanadaFootnote *
- 50% or more of its FTE employees have Canada as their ordinary place of workFootnote *
- 50% or more of its senior executives (Vice President and above) have Canada as their principal residenceFootnote *
Part 1: Mandatory and Minimum Pass Mark Criteria
Proposals must meet all mandatory criteria (Questions 1a and 2) and achieve the minimum pass mark for Question 3 in order to be deemed responsive and proceed to Part 2.
1 a. Scope
Describe your proposed solution and how it responds to the challenge. Include in your description the scientific and technological basis upon which your solution is proposed and clearly identify how your solution meets all of the EssentialOutcomes (if identified) in the Desired Outcomes and Considerations section in the Challenge Notice.
Mandatory - Pass/Fail
2. Current Technology Readiness Level (TRL)
Mandatory - Pass/Fail
Pass: The Applicant/Bidder has demonstrated that the proposed solution is currently between TRLs 1 and 4 (inclusive), and provided justification by explaining the research and development (R&D) that has taken place to bring the solution to the stated TRL.
Fail: The Applicant/Bidder has not provided sufficient evidence to demonstrate that the current TRL is between 1 to 4 (inclusive) including:
Describe the novelty of your solution and how it advances the state-of-the-art over existing technologies, including competing solutions.
Point Rated with Minimum Pass Mark
The minimum pass mark for this criteria is 4 points.
0 points/Fail: The Applicant/Bidder has not demonstrated that the proposed solution advances the state-of-the-art over existing technologies, including available competing solutions; OR
The stated advancements are described in general terms but are not substantiated with specific, measurable evidence.
Part 2: Point-Rated Criteria
Proposals that do not achieve the overall minimum score of at least 55 points out of a possible 110 points (50%) will be declared non-responsive and given no further consideration.
The overall minimum score is determined by adding the Applicant/Bidder's scores from the following questions together (1b, 3, 4-13).
Describe how your proposed solution addresses the Additional Outcomes (if identified) in the Desired Outcomes and Considerations section in the Challenge Notice.
If no Additional Outcomes are identified in the Challenge Notice, Bidders/Applicants will receive 10 points
4. Phase 1 Science and Technology Risks
Identify potential scientific and/or technological risks to the successful development of the proof of concept and how they will be mitigated in Phase 1?
5. Benefits to Canada
Describe the benefits that could result from the successful development of your solution. Applicants/Bidders should consider the potential benefits using the following three categories:
6. Phase 1 Project Plan
Demonstrate a feasible Phase 1 project plan by completing the table.
Note: Phase 1 cannot exceed 6 months and TRL 4.
7. Phase 1 Project Risks
Identify potential project risks (eg. Human resources, financial, project management, etc) to the successful development of the proof of concept and how they will be mitigated?
8. Phase 1 Implementation Team
Demonstrate how your project implementation team has the required management and technological skill sets and experience to deliver the project plan for Phase 1 by completing the table. A member of the implementation team can have more than one role.
Include the labour rates and level of effort for each member. A day is defined as 7.5 hours of work, exclusive of meal breaks. The labour rates and level of effort will be reviewed as part of the evaluation for Question 10.
If your business were to receive funding from Innovative Solutions Canada, describe what actions (e.g., recruitment strategy, internships, co-op placements, etc.) might be taken in Phase 1 to support the participation of under-represented groups (e.g., women, youth, persons with disabilities, Indigenous people, visible minorities) in the research and development of the proposed solution.
10. Phase 1 Financial Proposal
Demonstrate a realistic financial proposal for the Phase 1 project plan by completing the table.
11. Phase 1 Financial Controls, Tracking and Oversight
Describe the financial controls, tracking and oversight that will be used to manage the public funds throughout Phase 1.
12. Phase 2 Strategy
Describe a realistic strategy for the prototype development if selected to participate in Phase 2.
Responses should include:
13. Commercialization Approach
Describe your overall commercialization approach for the proposed solution.
Responses should include:
Questions and answers
Please refer to the tender notice for this challenge on Buy and Sell.
All incoming questions regarding a specific challenge will be posted here with the corresponding response.
If you have a question about a challenge, please send it to ISED-ISDE@canada.ca.
You can also consult the Frequently asked questions about the Innovative Solutions Canada Program.
A glossary is also available.