sept. 6, 2017
11.00 am to 11.45 am
BMW i3 Carbon Fibre Secrets Revealed
Sandy Munro of Munro & Associates, Inc. will discuss the material and lightweighting findings from his company’s extensive teardown of the BMW i3. During his informational discussion Munro will share the BMW i3’s notable use of carbon fiber, including key aspects such as the manufacturing of the vehicle’s carbon fiber life module, its polymer components, recyclability and safety. According to Munro, with its extensive use of carbon fiber, the BMW i3 introduced material and process technologies that have the ability to radically change the automotive manufacturing sector, as well as the aircraft, high-speed train, household appliance, computer and cell phone industries. During his presentation, Munro will discuss what his company’s extensive teardown and costing analysis uncovered and how it can be applied to future manufacturing processes and applications. The BMW i3 study marks the first time Munro reports were made available for public distribution.
sept. 3, 2019
3.15 pm to 4.00 pm
Boost your efficiency in composite production
From idea to series production – Everything from a single source, the best source.
From idea to series production-ready fiber composite solutions: At CCE Shanghai, KraussMaffei is highlighting its leading system expertise in developing and implementing series production-ready processes for fiber-reinforced lightweight construction. Includes Pultrusion, WetMolding RTM, Structure Composite Spraying.
sept. 3, 2019
3.15 pm to 4.00 pm
Boost your efficiency in composite production
From idea to series production – Everything from a single source, the best source.
From idea to series production-ready fiber composite solutions: At CCE Shanghai, KraussMaffei is highlighting its leading system expertise in developing and implementing series production-ready processes for fiber-reinforced lightweight construction. Includes Pultrusion, WetMolding RTM, Structure Composite Spraying.
sept. 6, 2018
11.05 am to 11.50 am
Composites in Future Mobility
The future of clean mobility will be shaped by new major trends where composites will have a key role to play: emissions reduction, powertrain electrification, future mobility.
Emission regulations and new city environmental policies are changing the game, requiring lower emissions. Lower emissions means weight reduction, both for thermal engine vehicles and electrified vehicles (for which the weight of the battery must be traded off).
New alternative clean powertrains bring new constraints that composites can address.
This conference presents the new potential for composite applications.
sept. 6, 2018
11.50 am to 12.35 pm
Composites solution for E-mobility
LG Hausys has developed EV battery pack housing cover and carrier with own plastic solutions. Cover with SMC and carrier with NCF glass fiber have achieved 30% and 35% of weight reduction respectively. Validations for both cover and carrier are completed and cover will be in serial production targeting 2020.
sept. 6, 2017
1.00 pm to 1.45 pm
Composites: Optimal technology to current and future stakes
Composite is quite a new technology at the industrial history level (compared to metal industry) and has several advantages (weight saving, tailored design, function integration…) to become the material of the future. Nevertheless in order to gain full acceptance, further improvement are still needed. We can in particular note:
- Product cost savings: mainly by consolidating functions
- Material cost decrease
- Development of new processes
- Development of an engineering chain
sept. 6, 2017
1.45 pm to 2.30 pm
Cost efficient approach for thermoplastic composite semi structural parts light weighting
Due to more stringent regulations to improve air quality, light weighting is an important topic in automotive industry. Powertrain parts, like oil pan, have seen a huge increase of injected plastics use. With thermoplastic composite, a next step can be achieved.
In the first part of the presentation, we will describe these new materials and associated processes.
A cost comparison with an injected thermoplastic oil pan will be shown with a specific focus on cycle time reduction and scrap reduction.
In the second part of the presentation, we will describe the technical support that was needed to ensure the success of this project.
sept. 3, 2019
1.15 pm to 2.00 pm
Development and trends in composite manufacturing
Over the past few decades, our cars have transformed into technological marvels, becoming safer, cooler, and more exciting to drive, while improving efficiency and sustainability. During this march of innovation, it may not have been so noticeable that the use of plastics has skyrocketed. Today’s cars are comprised of about 50 percent plastics by volume. BUT because plastics are typically lighter than other materials, plastics comprise only ten percent of today’s cars by weight. Few innovations provide a more wide-ranging performance and efficiency advantage than reducing weight. Those “advanced” materials—such as polymer composites, carbon fiber-reinforced plastics, 3-D printed plastic parts —are enabling remarkable improvements in safety, design, and performance and may usher in a whole new era in vehicle manufacturing and sustainability. Discover the latest trends & innovations in Composite Technologies and how it can contribute to an efficient mobility, through the eyes of Dr Henning, Managing Director of Fraunhofer Institute for Chemical Technology.
sept. 3, 2019
11.45 am to 12.30 pm
Enabling Further Use of Carbon Fiber SMC
- MAKING CARBON COMPOSITES ROBUST, FAST,AND AFFORDABLE
- Strength where you need it
- Saving weight
- Large volume production
- At affordable cost
sept. 6, 2017
3.45 pm to 4.30 pm
Fast RTM: high cadency composite manufacturing
Fast RTM is an industrial scale platform, whose goal is to demonstrate the feasibility of mass-produced structural composite automotive parts, using reactive C-RTM process. Thanks to an automated environment (loading and unloading) and especially developed cutting edge equipments, the “Fast RTM” platform is able to realise, in cycle time of 120 s, large (up to 3 m²), fully net-shape, functionalised and structural composite parts. To ensure traceability and quality of the produced parts, this platform is also fully instrumented with automatic data acquisition, process parameters traceability, energies consumption measurement systems and on-line non-destructive control systems.
sept. 3, 2019
2:00 pm to 2:45 pm
Flexible and economical process for mass production of hybrid lightweight composites
- Continuous Fiber reinforced composites have a large potential in modern automobile and related applications, especially for structural composites. With the use of UD tapes for local reinforcements, it is easily possible to place them alongside the load passes of the component to utilize its full strength potential as well as to increase the impact resistance where they are really need to carry the load.
- The automotive industry with its high requirements for high-volume and quality production requires a highly efficient production process with short cycle times.
- Dieffenbacher developed and introduced recently the new and state of the art Tailored Blank Line that copes all the requirements and therefore offers the benefit of a large-scale production in a precise, fast and economical way for the production of tailored fiber reinforced thermoplastic composites.
- The new tape laying system and new vacuum-assisted consolidation system developed by Dieffenbacher are the core of the Tailored Blank Line. Together with downstream systems, such as the handling robot and forming press, more than one million parts can be manufactured per year on just one line.
sept.6, 2018
10.15 am to 11.00 am
Fully automated direct fiber placement process for automotive large scale production
Voith Composites realised an industrialised production chain for the Audi A8 CFRP rear wall with a capacity of >300 parts/day. Among other things the net shape direct fiber placement (Voith Roving Applicator) and a segmented 3D stamping process have been developed. Bonding and riveting are realised in a fully automated assembly cell. Overall, a completely digitalised and automated production chain, that eliminated several conventional process steps, were developed based on “Carbon Production 4.0” and enabled a cost-efficient high volume CFRP production.
sept. 3, 2019
4.00 pm to 4.45 pm
Innovative Composite Lightweight Solutions for Automotive and Aerospace Applications
Fiber-reinforced plastics are becoming increasingly valued in the transport industry due to their very high specific material properties.
In the context of electro mobility, the weight-specific battery capacity has an increasing importance as an evaluation criterion for battery systems in the automotive industry. To achieve high values of >180Wh/kg innovative lightweight construction approaches are necessary. One of them is locally reinforced Sheet Molding Compound (SMC) as a resource and cost efficient process for manufacturing battery system enclosures.
An increasing number of identical parts per aircraft is pushing large-scale production processes such as Resin Transfer Molding (RTM) in the aerospace industry. Challenges, potentials and future directions of this development will be introduced at the example of an A350 door edge member.
sept. 3, 2019
4.00 pm to 4.45 pm
Innovative Composite Lightweight Solutions for Automotive and Aerospace Applications
Fiber-reinforced plastics are becoming increasingly valued in the transport industry due to their very high specific material properties.
In the context of electro mobility, the weight-specific battery capacity has an increasing importance as an evaluation criterion for battery systems in the automotive industry. To achieve high values of >180Wh/kg innovative lightweight construction approaches are necessary. One of them is locally reinforced Sheet Molding Compound (SMC) as a resource and cost efficient process for manufacturing battery system enclosures.
An increasing number of identical parts per aircraft is pushing large-scale production processes such as Resin Transfer Molding (RTM) in the aerospace industry. Challenges, potentials and future directions of this development will be introduced at the example of an A350 door edge member.
sept. 5, 2018
11.50 am to 12.35 pm
Innovative Glass Fiber Solutions to Automotive Market
Driven by the light-weighting and high performance requirements at Auto industry, Owens Corning is dedicated to developing the creative composite solutions in place of metals to achieve high strength/weight ratio, integration and cost efficiency; With that efforts, we are offering epoxy SMC, hybrid LFT and 3D-print materials; Our capabilities of modelling design, materials characterisations and reverse engineering will be definitely supportive to customers’ development.
sept. 5, 2018
11.50 am to 12.35 pm
Innovative Glass Fiber Solutions to Automotive Market
Driven by the light-weighting and high performance requirements at Auto industry, Owens Corning is dedicated to developing the creative composite solutions in place of metals to achieve high strength/weight ratio, integration and cost efficiency; With that efforts, we are offering epoxy SMC, hybrid LFT and 3D-print materials; Our capabilities of modelling design, materials characterisations and reverse engineering will be definitely supportive to customers’ development.
sept. 3, 2019
10:15 am to 11.00 am
New design scope for aerodynamic and acoustic optimization of the underbody of fully electrified vehicles
The all new Audi e tron, which is the first BEV model from Audi, is a technological breakthrough. The development of a specific platform, integrating the battery pack pushed Audi to rethink the design of many parts, and especially the underbody. In my lecture, I will present to the audience the functional requirements of the underbody. The changes of the car underbody, from a thermal model to BEV. We will then focus on the underbody system of the Audi e-tron and conclude by the new opportunities in underbody systems for BEV.
sept. 5, 2018
11.05 am to 11.50 am
New thermoset developments for mass production of automotive parts
The latest thermoset development for light-weight automotive composite applications in mass production are presented. A systematic approach is used to improve the mechanical properties of epoxy/carbon fiber SMC to achieve the highest performance in the industrial scale process. A new phenolic SMC is introduced that was molded into a battery box cover from a production electrical vehicle. The part has excellent fire retardant characteristics and passes the ECE R100 and GB/T 31467.3 tests. Furthermore, the PuriCoat platform for producing Class A surface quality, visible lightweight components within a very short cycle time is launched. The platform’s negligible emission levels address the growing regulatory demand for VOC-free solutions.
sept. 5, 2018
10.20 am to 11.05 am
Resins for high production rate process
In response to the need to design increasingly lighter materials for the automotive industry, Arkema has developed new reactive liquid thermoplastic resins for composite materials that are ever more efficient and easy to process.
sept. 6, 2018
9.35 am to 10.20 am
System Integrated Multi-Material Lightweight Design for E-mobility
The aim of the research project SMiLE is to get a fundamental understanding of the challenging multi-material lightweight design against the background of automotive serial production for battery electric vehicle bodies. Within the project two process routes were considered, the ultra-RTM technology for high-performance and cost-effective function-integrated CFRP-parts with thermosetting matrices and thermoplastic co-molding of continuous GFRP in LFT-D technology.
sept. 6, 2018
9.35 am to 10.20 am
System Integrated Multi-Material Lightweight Design for E-mobility
The aim of the research project SMiLE is to get a fundamental understanding of the challenging multi-material lightweight design against the background of automotive serial production for battery electric vehicle bodies. Within the project two process routes were considered, the ultra-RTM technology for high-performance and cost-effective function-integrated CFRP-parts with thermosetting matrices and thermoplastic co-molding of continuous GFRP in LFT-D technology.
sept. 6, 2017
3.00 pm – 3.45 pm
The ultimate manufacturing system in lightweight technology
The challenge for the mass-production automotive industry is to benefit from the lightness of composites at low cost.
Several developments have been and continue to be carried out in this objective.
They relate to:
- Materials: in particular use of thermoplastics reinforced by glass fibres.
- Tooling: automation of the entire production line, from preform assembly to netshape.
As small 40s to 90s cycle times can now be reached, paving the way for mass-production of composites for the automotive industry.
The present lecture present the industrial results of a development carried out jointly by a leading tooling manufacturer (PEI-Pinette) and a technical centre (CETIM).
sept. 6, 2017
3.00 pm to 3.45 pm
The ultimate manufacturing system in lightweight technology
The challenge for the mass-production automotive industry is to benefit from the lightness of composites at low cost.
Several developments have been and continue to be carried out in this objective.
They relate to:
- Materials: in particular use of thermoplastics reinforced by glass fibres.
- Tooling: automation of the entire production line, from preform assembly to netshape.
As small 40s to 90s cycle times can now be reached, paving the way for mass-production of composites for the automotive industry.
The present lecture present the industrial results of a development carried out jointly by a leading tooling manufacturer (PEI-Pinette) and a technical centre (CETIM).
sept. 3, 2019
11.00 am to 11.45 am
Thermoplastics: the way of the future – New developments
Fully automated, customised solutions for thermoplastic fibre composites.
sept. 3, 2019
11.00 am to 11.45 am
Thermoplastics: the way of the future – New developments
Affordable overmolded organosheet in mass production.
Valeo’s Thermal Front End Product Group has developed the first mass produced glass fiber composite structural part in the automotive market for the front end bolster of the Daimler GLE/GLS platform.
The process thermoforms glass composite inserts called “organo sheets” directly inside injection tools with the result being a one step net shape part able to be produced in high volume to meet customer annual volume. This innovative solution results in a 30 % weight save compared to metals.
sept. 6, 2017
9.35 am to 10.15 am
Think Composites, Think Automotive, Think Future! More Composites, better car
Automobile is moving at high pace, pushed by:
- new geopolitics: China has become in one decade the first automotive market in the world;
- new environment: Paris accord, depollution of large cities;
- new behaviours: car sharing, soft transportation, public transport;
- new technologies: electrification, ADAS, connectivity, support of car sharing;
Materials choice is a key element of the design and engineering of a car.
It conditions the weight, safety, comfort and cost of the vehicle.
A major trend is the smart use of a mix of materials.
Composite materials are very well positioned to respond to the challenges of the future:
GFRP (Glass Fibre Reinforced Plastics) for mass-production cars and CFRP (Carbon Fibre cars) for Premium cars.
This lecture is presented in connection with display of innovative automotive parts on the “Automotive Innovation Pole”.
sept. 3, 2019
9:35 am to 10:15 am
Together let’s enhance the automotive future
In recent years, the automotive industry has experienced a revolution.
The consumer revolution with a market epicentre which has moved to China.
The revolution of the way to consume vehicles, with the boom of mobility services.
The revolution of technologies (electrification, connectivity, autonomous vehicles).
The revolution of decision-making processes that govern these technological choices (stronger implication of governments).
However, the automobile product by itself is still today at the beginning of its mutation. The automobile is still a four wheels vehicle, with a steering wheel, seats and engine, in a steel box surrounded by plastic parts.
But the automobile in the next 20 years will dramatically change and the composites industry will drive these changes!
Innovations in the composites will unfreeze the design, production and consumption modes of vehicles.
This lecture will present the ways these innovations will lead to development of composites in the automotive industry.
Together, let’s enhance the automotive future!
sept. 6, 2017
10.15 am to 11.00 am
Towards lightweight vehicles: design and technology stakes
As mainstream worldwide car OEM, PSA manage the average weight of its products with attention and plan to go on saving weight from a generation to another. In order to reduce the average weight of the cars, all tracks are explored: design optimization, aluminium and composite implementation.
So far, the first technological step stands as aluminium until composite become competitive for high volume production. Actually, in one hand, composite is already competitive for a few specific technical perimeters: tailgate and rear floor. In the other hand, there is still some way for composite to be competitive in a larger area of products.
sept. 5 & 6, 2018
9:30 am to 9:35 am
Welcome address
sept. 3, 2019
9:30 am to 9:35 am
Welcome address