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Carbon Fibre:

Enabling Mass Production Technologies for vehicle

lightweighting

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Engineering, Prototyping & High Volume Production

Composites

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Key Drivers – CO2 Emmissions:

• All OEM’s must make cars that comply with EU & Global Legislation

• From 2012 - 2020 mass based CO2 limits will be applied to new cars

• OEM’s must address the Sustainability challenge in a cost effective

manner, whilst maintaining vehicle attributes & making vehicles that

appeal to their customers

Hybrid Elec Vehicles

Flywheel [Kinetic]

Plug in Hybrids

Electric Vehicles

Combustion

Transmission

Driveline

Powertrain Efficiency

Weight Efficiency

Vehicle Architecture

BIW & Closures

Chassis parts

Material application

Joining technology

LCA

Weight v attributes

Aerodynamics

Rolling resistance

PT & Thermal

Energy management

- Chassis systems

- Electrical

Climate systems

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Weight Reduction

Global convergence of CO2 emissions targets

CO

2E

qu

iva

len

t/km

Co

nve

rted

to

NE

DC

Te

st C

ycle

10

1g

/km

19

g/k

m

CO2 Equivalent/km converted to NEDC Test Cycle

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Weight effect on CO2C

O2

g/

km

PetrolDiesel

Hybrid

Modus

Citroen C2

Focus

Jaguar S 2.7

Jaguar XF 2.7

Insight

Prius

Civic

Lexus GS450h

Lexus RX400h

Lexus LS600h

Citroen C1

50

100

150

200

250

300

500 1000 1500 2000 2500

LWV Vehicle

weight saves

combined with

PT & Parasitic

loss reduction

CAN get us to

CO2 targets

Kerb weight (kg)

Engineering activity to reduce CO2 emmission

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Body Design & Analysis:

Simulation Test

Average Acceleration (g) 24.9 25.0

Residual Length (mm) 135 134

• Body Engineering & Optimisation:

• Compliant with FIA Regulations

Composite Enabling Technologies:

Engineering Design: Design for Performance

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Brief Description:

Develop affordable carbon fibre body

architecture, delivering significant weight

saving and high volume production

feasibility

Project Overview:

Funded by Technology Strategy Board

High Volume CFRP Production

36-months

Project value £16.8 mil

Project Partners:

VarCity Programme:

Vehicle ARchitectures for CITY cars

Composites Enabling Technologies

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Composite Business Development:

WP1

Vehicle (Body) Architecture

Design Concepts &

Vehicle Integration

(JLR) WP2

CFRP Material

Selection & Development

(CYTEC)

WP3

CFRP Component

Manufacturing Process

Development

(PENSO)

WP5

Adhesive Material

Development

(SIKA)

WP8

Demonstrator Body

Build

(PENSO)

WP9

Virtual testing (CAE)

Physical testing

LCA & Cost Analysis

(JLR)

WP7

Demonstrator Part

Manufacture

(PENSO)

WP10

Dissemination

&

Exploitation

(JLR)

WP6

Joining & Fixing Strategy

& Fastener

Development

(AVDEL)

WP4

Body Assembly

Automation & Tooling

(EXPERT)

Te

ch

no

log

y D

eve

lop

me

nt

De

mo

ns

trato

r D

eve

lop

me

nt

VarCity Workstreams and Partners:

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Composite Enabling Technologies:

VarCity & Partner Workstream Outputs:

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Composite Enabling Technologies:

Manufacturing Processes:

Preform & Lay-up Automation

Semi-Automatic &

Fully Automatic Bonding

Materials:

Large tow CF, NCFs & Textiles

Materials:

Snap Cure Resin Systems

Legacy Materials

Design for Performance

Hot Compression Moulding

High Pressure Resin Transfer Moulding.

2014

Autoclave Processes

2015 2016 2017 2018 2019 20202013

High Volume Vehicle or Systems e.g. closuresVolume >50,000BIW weight <150kgInvestment <£40mPiece Costs <£2,000

High Performance Super Cars:Volume <3,000BIB weight <160kgInvestment <£5mBIB unit Costs <£10,000

Design for Performance,

Manufacturing & Cost

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Composite Enabling Technologies:

Simultaneous Tooling Development:

Substantial Research and Development into manufacturing processes for high volume CFRP production, simultaneously aligned with tooling development to suit product performance and cost requirements.

Prototype tooling in aluminium

Low volume production using aluminium tools

High volume production using steel tooling

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Composite Enabling Technologies:

Hot Compression Moulding & High Pressure Resin Transfer Moulding:

High tonnage press facilities with large platen formats, allowing the production of large integrated components.

High pressure RTM equipment automatically linked to specific presses.

Ultrasound NDT Equipment for panel inspection. (Lamination characteristics, bonding characteristics etc.)

Inspection Booth

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Composite Enabling Technologies:

Research Industrialisation:

• Composites press facility expansion with semi-automated and fully automated press lines.

• Fully automated BIB assembly facility

• Tool Room expansion for increased capacity requirements

• Full “turnkey” composites facility from product engineering through to volume production supply.

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Penso - January 2015

Thank you for your attention