A specialist service offered by 4Four Associates is composites structures design. After graduating in 1984, Matthew joined John Barnard and Steve Nichols in the McLaren design office where, three years previously, John had introduced to F1 the first-ever single-shell moulded carbon fibre monocoque (chassis). From that moment on carbon fibre composite structures became ubiquitous in F1 as well as many other forms of motorsport. Since that time designing composite structures and crash structures has become a mainstay of Matthew's services offered to clients in increasingly diverse industry sectors, where the benefits of lightweight, structurally efficient components can be exploited.
4Four Associates now provides design services and consultancy to the Automotive, Aerospace, Motorsport, Energy, Defence and Marine industries who are all exploiting the benefits of lightweight, highly efficient composite structures. Apart from passing on the technical lessons learnt from close to 40 years' involvement in designing composite structures, we find a common requirement for nearly all our clients is the need to 'think outside of the box' and not try to reproduce a previously-made metallic component with a similar geometry now comprising composites. In addition, the need to consider how components will be manufactured from the outset is of paramount importance. Being able to connect the design process with the best manufacturing process from the start is all part and parcel of our services.
Case Studies
Defence organisation: submarine project
Direct appointment working as a consultant for an SME developing composite design and manufacturing processes for new telescopic masts for submarines. A new prepreg material construction was proposed for two telescopic masts, each approximately 5m long and up to 800mm in section. In addition to the structural requirements, the design process required a detailed exploration of all manufacturing options such that the design intent for weight, stiffness and strength could be met for all operational loads.
Aerospace customer
Direct experience in the concept design and analysis of complex duel-skinned carbon/honeycomb prepreg composite panels for testing a new large-scale ducted turbo-fan aero engine. The pylon to wing structures operate in a temperature range of 100-350deg C so the design and manufacturing process has to be carefully considered for the inclusion of a cyanate ester resin system. For one particular project, a novel Kevlar seal/hinge was designed to accommodate the complex motion of the engine and wing interface. The design took its inspiration from the front wing endplate 'skirts' originating in F1 30 years previously.
Wind energy turbine blade
Engaged as a project manager for a UK-based wind turbine manufacturer. Managed off-site mainland prototype manufacture of composite blade tooling to strict design requirements and project timetables.
Aerospace customer
Engaged by a large US Aerospace client to conducted an in-depth design and manufacturing feasibility study for a new carbon-composite aero engine gearbox casing structure.