Case Studies
Composite Hybrid Bus Body
Energetx Composites was contracted by a manufacturer of hybrid transit buses for the fabrication of composite bus bodies. In working with our partners, Energetx Composites developed a laminate schedule, as well as undertook the Finite Element Analysis. Energetx is also fully capable of manufacturing new molds and fixtures within our manufacturing facility.
Energetx was initially contracted for the manufacture of the large structural composite components relating to the bus, however, as the customer recognized our experience and breadth of capabilities, Energetx was soon asked to undertake the assembly work as well.
Throughout the project, Energetx worked collaboratively with the customer’s engineering team to make the project a success. In addition to the composite work, Energetx also drilled all the holes, installed compression fittings where needed and installed all metal backer plates. Energetx also installed the conduits into the chassis. The materials utilized for the construction were E-glass, carbon, balsa, and foam, utilizing the VARTM process.
In summary, Energetx provided the customer with 14 all-composite bus bodies, taking the project from mold to post paint, while continually looking for ways to improve the overall project for the customer.
Nacelle Program
A leading wind turbine OEM came to Energetx Composites for assistance in manufacturing nacelle components for their North American nacelle assembly plant. In less than 4 weeks, Energetx Composites had two sets of nine tools into production. Within five days, we were manufacturing eighteen parts per day at a 25 minute takt time. We also achieved a one piece flow in a purely laminate production setting.
Over the course of the project, we manufactured over four hundred parts utilizing 9,300 square feet of tooling surface. Similar to our other projects, we were able to manage the man-power demand through our partnership with Grand Rapids Community College’s composite technician training program that was taught at our facility in Holland.
Ultimately, we became an approved supplier for this organization within a thirty day period and continue to grow our relationship with them.