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1
Innovations in Composite
Engineering & Light-weighting
Steve Fletcher - BEng (Hons) CEng MIMechE
Head of Engineering
2
Company Overview
Consulting
Composite
Technologies
Project Management
Body Engineering
FEA Simulation / Crash
Light weighting
EV Design
High Volume Composites
Cost Effective
Tooling & Machining
Integrated Composite Systems
Trim Development
Electrics & Electronics
Prototype build
Niche System Production
Series Production
Special Operations
3
Company Overview
ENGINEERING CENTRE
Coventry, UK
ENGINEERING OFFICE
London, UK
Pune, India
Accreditation
TS16949 : 2009
ISO9001 : 2008
Core Competencies
Consulting
Composite Technologies
Special Operations
Clients
Strategic Alliances
Cytec (Oct 2015)
Pricol Technologies (Jan 2015)
4
History
2005
Management
buy out of P+Z,
Rebranded
Penso
Consulting
2006
Complete
interior design,
manufacture &
production
supply Brink
Carver ‘One’
2007
Fiat Professional
Specialist turnkey
vehicle programme
– engineer and
manufacture taxis
for UK public hire
sector
2008
Engineer and
manufacture
London Specific
Vito Taxi for
Mercedes Benz -
Full European Type
2 approval and
homologation
2009
Spyker C8 Aileron
complete vehicle
engineering,
interior trim and
convertible roof
system for Spyker
derivative.
2010
ISO9001 and
TS16949
accreditation
2011
Tier-1 supplier into JLR L538C Evoque Convertible
L405 LWB
CX75 engineering &
Composite Body
Structures
X152X Prototype, Tonneau
ETO engineering support.
Project Donington
engineering and build.
VARCITY Megacity.
2012
Supply of Production,
Interior Trim for
Morgan 3 Wheeler
2013
Re-Accreditation
of ISO9001 and
TS16949
Support Product
Launch L405 LWB
2014
L538C
L538C ADV
CDRM Models
P231
SP1 L322
SP2 L405
X261
SP = Special Project
2015
Bimini Hood
X590
X760 LCN
CF Train Door
5
Company Growth
Turnover
Penso has grown rapidly over last few
years – diverse customer base.
Turnover tripled over last 5 years
Forecast for 2015: £32m
Growth supported by renaissance in UK
based Manufacturing.
UK Government Support
National (Innovate UK)
Local (City Council)
Legislation is driving need for lower
emission vehicles.
6
Lightweight Composites
From prototype to volume production
7
Lightweight Composite Technology
EU CO2 Legislation as ‘Technology Driver’
Average UK new car CO2 emissions & EU
new car CO2 regulation targets
2020: 95g/km (legislation)
2025: 75g/km (under review)
8
Composite Enabling Technologies
9
Composite Enabling Technologies
Design for Performance,
Manufacturing & Cost
10
Process flow developed over the last 5
years on multiple composite
engineering programmes
Concept Engineering
- Primary joint and beam stiffness and
strength calculated.
Detail Design Engineering
- Full ply stack definition and
optimisation
Manufacturing Engineering
- Producibility assessments
- Cuts & Darts
- Automated Ply-Book generation and
digital data output
State of the Art Design & Simulation Tools & Processes
Design for Performance, Manufacturing & Cost
11
Advanced Simulation Tools
- Crashworthiness
- NVH
- Durability
- Optimisation
State of the art materials modelling
methods
- Penso materials modelling methods
developed from existing ASTM
methods to align with latest technology
requirements
Advanced toolset allows detailed
analysis of joints and ply stacks
Simulation Methods for Composites
Design for Performance, Manufacturing & Cost
12
Advanced simulation technologies applied
Material card data developed to enable predictive
methods.
- Tests are developed variants of ASTM standard
methods.
Composites Crashworthiness Simulation
C-X75 30FFB Crash C-X75 30FFB Crash
Penso Material
Development Process
Design for Performance, Manufacturing & Cost
13
Optimisation setup Optimisation - Initial
Laminate Optimisation
Continuous phase - 1 Continuous phase - 2 Continuous phase - 3 Continuous phase - 4 Continuous phase - 5 Continuous phase - 6 Continuous phase - 7 Continuous phase - 8 Continuous phase - 9 Continuous phase - 10 Continuous phase - 11 Continuous phase - 12 Continuous phase - final Optimisation Discrete phase Rationalise Optimisation
results
Design/manufacture requirements Manual optimisation
Local reinforcement for
attachment points
Final layup
C-X75 Tub
Includes Penso developed algorithms to optimise for Material & Process
costs in parallel with mechanical performance and weight
Optimisation
Triangle
Weight
Performance
Cost
Design for Performance, Manufacturing & Cost
14
C-X75 Phase 1 Body Actual
BIW Weight: 160kg
BIW Torsion Mode: 75Hz
Torsional Stiffness: 56kNm/o
Bending Stiffness: 15kN/mm
Suspension Local k’s: 14-59kN/mm
Lamborghini Aventador
249.5kg (+56%)
44.9Hz (-40%)
35kNm/o (-38%)
Performance Benefits
Design for Performance, Manufacturing & Cost
15
Manufacturing Processes:
Preform & Lay-up Automation
Composite Enabling Technologies
16
1. Raw material
defrost 2. Nesting and
kit cutting of parts
(Pattern cutting)
4. Preforming
and Trim 3. Ply stack
7. Trimming
(5-Axis CNC) 5. Advanced
demould
6. Press forming
(Hot Compression
Mould Press)
demould & set up
8. Sample
Inspection
PPCP – Process Development
17
<10 min cycle time
Preforming
(Penso alternate method)
and Trim
Ply stack
(Penso alternate technology)
Trimming
(5-Axis CNC)
using alternate method
Advanced
demould
(Penso alternate method)
Press forming
(Hot Compression
Mould Press),
demould & set up
27 min 15 min 25 min 10 min 20 min
Preforming
(vacuum bladder)
and Trim
Laminating Trimming
(5-Axis CNC)
using manual fixings
Demould Press forming
(Hot Compression
Mould Press),
demould & set up
<10 min <10 min <10 min <10 min <10 min
INITIAL PROCESS
IMPROVED PROCESS
27 min cycle time
PPCP – Process Development
18
10 min
cycle time
PPCP – Process Development
5. Demould
(Penso alternate method)
19
Hot Compression Moulding
High Pressure Resin Transfer Moulding
Composite Enabling Technologies
20
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)
Inspection Booth
Composite Enabling Technologies
21
Penso’s Lightweight Technology
State-of-the art hot
compression moulding
Cycle times <7
minutes
Press forming
10 registered patents suited to use in the
automotive, rail and aerospace industries
HP-RTM
State-of-the art high-
pressure resin transfer
moulding
Cycle times <5 minutes
Composite Enabling Technologies
22
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.
Tooling in aluminium
Low volume production using
aluminium tools
High volume production using steel
tooling
Composite Enabling Technologies
23
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.
Tooling in aluminium
Low volume production using
aluminium tools
High volume production using steel
tooling
Composite Enabling Technologies
24
Further Development & Growth
Penso next investment
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.
25
Steve Fletcher Head of Engineering
steve.fletcher@penso.co.uk
M: +44 (0)7508 225 762
Penso Consulting Ltd
Woodhams Road
Coventry
Warwickshire
CV3 4FX
United Kingdom
T: +44 (0)2476 217760
www.penso.uk.com
www.linkedin.com/company/penso
www.twitter.com/PensoGroup
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