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EMKAY
CORE SOLUTIONS FOR THE CORE INDUSTRY
HEAT TREATMENT AVAILABLE AT EMKAY 

FOR INFORMATION ON PROCESS TIMES AND PRICES GET IN TOUCH.
Team Bath competing in the endurance section of the competition.
Team Bath Racing Celebrating!
Team Bath Racing in line for scrutineering!
          Team Bath Racing
Team Bath Racing brought home a lot of silver!
Team Bath Racing in the Pit Garage!
Tom Peirson-Smith being interviewed at the Silverstone race track.
New Sheet Sizes!
EMKAY SUPPLYING ROHACELL IN NEW SHEET SIZES
We are happy to announce we can now supply our customers with 1/8's (630mm x 630mm) of a standard Rohacell sheet (2600mm x 1350mm) The 1/8's are available to be cut from IG-F and IG-UF
 
PDQ PAYMENTS

Emkay have two payment methods available. You can choose whichever suits your company best!

Option 1: Over the phone PDQ system payment on ordering

Option 2: 30 Days at end of month payment account 
ROHACELL 51 HF!
 
EMKAY ARE NOW STOCKING ROHACELL 51 HF!
 
Please contact us to request a price list. 
Emkay Plastics Ltd
Composite House
Mission Road
Rackheath Business Park
Norwich
Norfolk
NR13 6PL

Tel: +44 (0) 1603 746 000
Fax: +44 (0) 1603 746 001

info@emkayplastics.co.uk

 
Team Surtes out on the track
Team Surtes ready for action
Team Surtes in the Endurance race
Warwick Racing raring to go at Silverstone
Warwick hard at work in the pit garage
Making last minute amendments to the WR car in hope of passing scrutineering.
Warwick Racing 
Araan Dass in the Drivers Seat
Warwick Racing
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EMKAY STUDENT SPONSORSHIP UPDATES-PART 1
 

This year EMKAY sponsored Formula Student teams, an unmanned aircraft team and a human powered submarine team. Each year we supply universities and schools with the free issue of our Rohacell to help with these projects.  We supply schools in Norfolk to help with their Design and Technology projects and universities Worldwide with other projects,mainly Formula Student, but this year we had teams contact us from different competitions so we decided to open up our sponsorship to other areas . Emkay are extremely proud to be part of the sponsorship scheme in which we feel all teams involved have made amazing achievements. Some of the students even get to set off around the world to compete in different competitions facing new nations and new challengers!
Congratulations to all and Good Luck in the next chapter of your journeys!
Formula Student 2015

Thousands of students from all over the World traveled to Silverstone to compete in this year's competition.  We spoke to the teams we sponsored and asked that they summarize Formula Student Silverstone in their own words....
 
Team Bath Racing-University of Bath 
 
“Incredibly proud of what we managed to achieve this weekend. To prove we had the pace to run with the best teams in the world, despite being a ’rookie’ team, was really satisfying. To also win the main event on Sunday (the 22km Endurance) was something I never could have imagined doing before the event. We have now equaled Bath’s highest result at any event, with 4th overall out of 100 teams. Our motivation is now very high going into Austria and Spain, where we hope to go one better and stand on the podium.”
– Tom Peirson-Smith, TBR15 Project Manager
 
“A combination of an aggressive setup on the rear dampers and a narrow safety margin on the front lower wishbone resulted in buckling of the rearward linkage in that component. This led to the whole front left corner of the car facing in the wrong direction. This was a real problem that many of the other teams seemed convinced we would be unable to fix, as the car was wheeled back to the pits on a trolley. Fortunately the team had been working on upgrading the wishbones to a stronger, lighter set made from carbon tubes. The final components had just been completed in Bath on the Thursday and were rushed up to Silverstone for assembly on the car.”              - Josh Gillman, Suspension Design, TBR15
 
“A manic day on Saturday included Acceleration, Skid Pad and Sprint events. Different settings are required for each event, so slick changes were critical to achieve optimum vehicle setup and improve performance. A locked differential was used for Skid Pad, with a stiff rear antiroll bar, which was reversed for the Sprint event. For the Acceleration, the rear wing was put into low-drag mode, with rear tyre pressures and dampers softened. Further testing before Austria and Spain is being used to identify additional changes that may be of benefit, helping to reduce event times.”       - Michael Graham, Car Setup, TBR15
 
“Driving TBR15 has been overwhelming from lap one to the finish line. Race cars are often either too aggressive or simply too slow, but the team managed to find the perfect balance for our new car.  High-speed corners in particular feel incredible, as you really get to notice the effect of those massive wings! All in all, the car and the event have been amazing. I am confident that with TBR's team-spirit and technical skills, we'll be even better in Austria and Spain.”
- Max Teichert, Endurance Driver,
for 
 
"THURSDAY sees the beginning of the FSUK competition, with a mixture of Scrutineering and Static Events being carried out over the Thursday and Friday period. The team was fortunate enough to have the Business, Design and Costing events all on Thursday, meaning that by 4pm, the team could focus solely on the Dynamic Events for the rest of the week.
The Static events proved to be less successful in 2015 than previous years, with the team struggling for points, particularly in the Costing event. Despite improving the quality of static presentations from 2014, the competition had also improved massively, meaning the team finished 12th in Design, 22nd in Business and 54th in Costing.
The rest of Thursday was used to complete the majority of checks on the car, including Scrutineering and the Tilt Test. The Scrutineering procedure ensures that the car complies 100% with the rules for the competition, as well as checking that the driver kit is of the highest safety level. The tilt test is then also used to confirm that fuel does not leak from the car. This helps follow a logical progression within the scutineering process, whereby the car is checked to be legal within the rules, then checked that it does not leak fuel, before having the noise level checked to be under 110 dBC and finally the brakes checked to make sure all four wheels are able to be locked.
Thursday finished with the team having received 4 of the 6 safety stickers, leaving just the Noise  Test and the Brake Test to be completed.

FRIDAY began with much difficulty for TBR15, with the Noise Test proving a particular challenge. The 2015 rules see a change in weighting of the noise level from dBA to dBC, meaning all the cars are required to be quieter than their 2014 predecessors. Despite the addition of a turbocharger, the team struggled to pass the Noise Test, taking several attempts to come under the maximum noise level. This was eventually achieved through the modification of the silencer exit point, to reduce reverberation from the rear wing endplates. After receiving the Noise Test sticker, the team moved onto the Brake Test, where the car suffered a rather severe wishbone failure during one of the runs. Thankfully, a spare set of full carbon wishbones were rushed to the track, and by late afternoon, the car was completely fixed. Unfortunately, the failure meant that TBR15 had to be-scrutineered, and this meant providing the judges with extra data sheets to prove the new wishbones would out perform the previously used steel ones. After a lengthy discussion in the scrutineering zone, the car was given the all clear, and the team attempt to pass the Brake Test once again.
On SATURDAY Formula Student really begins to get going, with the first of the Dynamic events. This is a particularly challenging day for the team, with the Acceleration and Skid Pad events in the morning, followed by the Sprint in the afternoon.
As well as this, the team had to complete the Brake Test that had destroyed the car the previous day. A slightly less aggressive setup allowed TBR15 to pass on just the third attempt, bringing a huge round of applause from the crowd, not just TBR members.
The car was then tested in the straight-line Acceleration event, with Will Charles setting a competitive banker-time. This was then repeated for the Skid Pad event, where Will set further good times without driving too close to the edge. Some setup changes were made to the car, so that our 2nd driver Mark Tranter, was then able to drive the car right on the limit, without fear of spinning. He was able to improve on both the banker times set by Will, resulting in a respectable 13th in Skid Pad and 18th in Acceleration.
Saturday afternoon saw the running of the Sprint Event, where the team knew the car would run well. Unfortunately, the setup of the car proved to be less than optimum, meaning the team finished in 12th - much lower than expected, with some incredibly quick times being set by the big European teams. It was clear than some major chassis and powertrain changes would be required overnight to become competitive in the endurance event on Sunday afternoon.
 
SUNDAY holds The Endurance Event at Formula Student, this is where the majority of points are on offer, with 400/1000 up for grabs.
As one of the faster cars from the Sprint on Saturday afternoon, TBR were given a late slot to compete in the Endurance - something that did not please the team with heavy rain forecast for  some point in the afternoon.
Unlike many other Formula Student events, the UK edition does not offer the fastest teams the opportunity to complete their endurance run earlier in the day if rain is forecast for the afternoon, which can have severe consequences on the overall result.
As TBR15 entered the track in the early afternoon, the sun was no longer shining and dark clouds began looming over the circuit. 12 competitive laps by our first driver, Kevin Johnson (including overtaking our rivals Oxford Brookes on track) ensured that at the halfway mark, the team was in an extremely strong position. After the driver change, Max Teichert went out and set a blistering pace, picking up the fastest lap of the day and a final endurance time 2.5 minutes faster than the next best team!
More importantly, as Max pulled in to complete the Endurance Event, the heavens opened and torrential rain fell causing the event to be red flagged. When the track was re-opened, all teams were on wet tyres and thus, could not come near to our time. As a result, Team Bath Racing ended the weekend as the top UK team and finished 4th overall, just 2.4 points behind 3rd place, equaling Bath’s best ever finish."

 

Emkay would like to wish Team Bath Racing our congratulations, what an amazing end to the first round of Formula Student Competition!
Team Surtes-University of Surrey
 
Matt Smith a Placement Student from Team Surtes wrote;

"Team SURTES would like to thank you for your continued assistance throughout this academic year. It's been an extremely successful year and all the hard work from the entire team has paid off. Overall, we achieved our best ever result with a 12th place finish globally and a 5th place finish in UK, which the whole team is over the moon with! At the start of the year, we set a goal of Top 15 Global and Top 5 UK and we are very proud to say we have exceeded these targets. This result was made even sweeter by being the fastest UK team in the Acceleration event and achieving a 2nd place finish in the Cost event. We were also able to get more testing completed prior to the event than ever before."


 
Congratulations Team Surtes , what a great result!
WARWICK RACING -University of Warwick
 
 

"The IMechE Formula Student competition at Silverstone last week was a great learning curve for the team. Unfortunately, we were unable to successfully pass Scrutineering in time for the dynamic events, thus were unable to compete in Acceleration, Skid Pan, Sprint, or Endurance. This was due to many minor faults occurring over the week, culminating in a pedal box mount failing early Sunday morning in brake test, rendering the competition over.

The team successfully completed their static events, placing:
12th - Business Presentation
47th - Cost and Sustainability

57th - Design

This led to a finish of 57th overall, 19th in the UK, with 171.9 points.

We are back at the workshop today, busy making plans for how to perform more successfully at Formula Student Germany in a couple of weeks, and learn from the experience gained at Silverstone.

The team would like to thank everyone for their support this season. We will be releasing a fully detailed report of the UK and Germany competitions once we are back from Hockenheim in August."

Such a great team and such a shame on the Silverstone result, BUT, Emkay have every faith that the Hockenheim round will go just fine for the team! Good Luck Warwick Racing we look forward to the update on your return!
Bath University take part in The Unmanned Aircraft Systems Challenge
 
 The UAS challenge requires the teams competing to undertake a full design and build cycle of a UAS with specific mission objectives from the start of the academic year before competing in a final fly-off. This year we sponsored Team Bath. They sent us their write up of the team's experience;

 
''Team Bath Drones left the awards ceremony for the IMechE UAS Challenge last week empty handed and a little perplexed, but can hold their heads high in the knowledge that they produced the fastest, most efficient, and best handling aircraft on the field, and without question the only viable answer to the competition's humanitarian aid delivery scenario. The team were a victim of their own success in many respects, being the first to successfully navigate the course autonomously and doing it with such effortless speed that the IMechE's safety pilot deemed the margin for error too small at the boundary of the airfield and aborted the flightplan early.
The safety call was sensible but the course layout, a guarded secret until the competition day, was better suited to less capable aircraft. But for this decision it seems likely the team would have produced the best performance of the competition by a clear margin.
 
The competition was the first of its kind, and despite Bath's plight it was very enjoyable and an overwhelming success. The organisers did a great job of managing proceedings on the day and everything ran smoothly for such a complex event on its first outing. The atmosphere was fantastic and the camaraderie amongst the different universities was laudable. Even the weather failed to make its usual mockery of things with proceedings opening on the hottest day of the year, followed by some refreshing light cloud cover on the second day.
 
The competition scenario was that of a humanitarian aid delivery mission.
The vehicles were tasked to autonomously navigate a series of waypoints, identify an alphanumeric character on the ground, and deliver two 1kg aid packages to that marker. Bath was not the only university lamenting their ill fortune, however, with the first few teams struggling to get their aircraft off the runway or keep them airborne; technical hitches abounded as it became increasingly clear that the challenge was far from trivial.
 
Bath had no such technical problems and pre-flight setup and checks proceeded without incident. As the aircraft, the "Stingray", left the runway, an initial faltering dip gave way to soaring, graceful flight. The aircraft picked up speed and altitude, and was soon cruising effortlessly just below the competition's speed limit of 30m/s (67 mph). The expert piloting of Wojciech Wasinski was smooth and his wide, banking turns produced a confidence-inspiring flight. As the first autopilot stage was enabled, the flight stabilisation kicked in and the Stingray looked like it had been put on rails. It was fast, quiet, stable and agile. Feeling confident, the second autopilot stage was enabled, and the aircraft began to fly of its own accord. It navigated the waypoints with astounding speed, and in no time was headed for those at the far end of the airfield. As the Stingray receded into the distance, nerves began to rise. Nobody had flown this section of the course autonomously, nor at anything approaching this speed. The aircraft banked to the left, and for a moment it looked like circling around. Then it banked to the right again. Later analysis showed that it was still following the course, but with only a short distance separating the final waypoint and the boundary of the airfield the safety pilot had a fraction of a second to make the call and he rightly asked Wojciech to take manual control to bring the aircraft back.
 
The switch from fully automatic to fully manual control resulted in an abrupt drop in throttle and a destabilising rolling moment, and as the aircraft floundered into the camouflage of the distant treeline it was too late for corrective action. The last fleeting glimpses of the Stingray saw it execute an arcing roll before plummeting into the woods. Upon retrieval the fuselage was intact despite the speed of the crash, but one of the wings was beyond repair. The team never had the opportunity to demonstrate their payload delivery systems, nor their impressive alphanumeric marker detection systems - something that no team before or after managed to exhibit. The flight was unarguably the best of the day in every respect and while the second day saw teams successfully drop payloads to meet more of the competition's objectives, the Stingray's handling and performance remained unparalleled throughout. 

 The team can be proud of their achievements - the innovation and sheer quality of their design and manufacture stood out above the other entries.
Their efforts were not lost on the other teams, the volunteers or the industry attendees, with an excited buzz surrounding the aircraft. Features not found on any other aircraft included the efficient blended-wing-body design, the carbon monocoque construction, the auto-switching dual-redundancy in the communications channels, and the automatic tracking antenna for high-bandwidth video downlink, making it the only aircraft capable of flying a 20km round-trip all the while retaining communications with a ground station. The team deserve wholehearted congratulations for their immensely impressive performance.

 Thank you for providing us with the Rohacell the material was superb quality. 
We have used it in our sandwich structure, laser cutted ribs and internal components. " 
 
Congratulations to the team who designed and built a fantastic unmanned aircraft! We look forward to seeing what the team will bring next year!
Look out for PART 2 of Emkay's student sponsorship updates coming soon!
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