EDAG INSIGHTS 1/15...EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 2 Inspired by nature. Additively manufactured. And the ultimate in lightweight design. The ”EDAG Light Cocoon“ is a

EDAG INSIGHTS 1/15 - EDAG LIGHT CoCooN 1

EDAG INSIGHTS 1/15

EDAG LIGHT CoCoon

PROGRESSIVE AUTOMOBILE DESIGN AND

BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES

AND ADDITIVE MANUFACTURING PROCESSES


Inspired by nature. Additively manufactured. And the ultimate in

lightweight design.

The ”EDAG Light Cocoon“ is a visionary approach towards a compact,

dynamic sports car, with a fully bionically optimised, additively manufactured

vehicle structure combined with a weatherproof textile outer skin.

EDAG LIGHT COCOON PROGRESSIVE AUTOMOBILE DESIGN AND BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES AND ADDITIVE MANUFACTURING PROCESSES


EDAG INSIGHTSCONTENTS

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5

7

9

13

14

20

21

The 3D print revolution has begun

Technology roadmap of additive manufacturing

EDAG Genesis was only the first stept

EDAG Light Cocoon:

The statement for future lightweight construction

Social relevance and sustainibility

The concept in details:

Drive concept and package

Fugenlos beweglich: The Light Cocoon‘s spoiler

Personalisation via accounts

Conclusion

Editorial


THE 3D PRINT REVOLUTION HAS BEGUN.

Despite the large number of conceivable

processes on the market, the general principle is

the same: the material is built up layer by layer,

without the use of tools, and only a 3D data

model of the product must be available as input

data. This method opens up enormous freedoms

in development and design which were not pre-

viously possible, due to restrictions in production

imposed by the classical primary forming, re-

shaping and machining manufacturing processes.

Additive manufacturing processes put us in a

position to be able to adopt and copy nature‘s

construction principles. Developed functionally

and evolutionarily into optimised structures from

which man can learn. And the entire process is

tool-free, resource-saving and economical.

Processes such as the thermoplastic-based FDM

process offer the chance of integrating fibre

elements, to represent structural parts. As a

result, completely new concepts for ultimate

lightweight design in automobile development

are already emerging.

Everyone is talking about „3D printing“. After consumer printers have flooded the market,

industrial applications will follow. Generative manufacturing processes or additive

manufacturing will leave the prototype status behind and add a new dimension to the classical

manufacturing methods. Additive Manufacturing has long been in use in the automotive and

aerospace industries and in medical technology. Above all, small parts and Prototypes can be

produced quickly, and without the use of tools.


TECHNOLOGY ROADMAP OF ADDITIVE MANUFACTURING

SLM – Selective Laser Melting

The principle of this process is similar to

electron beam melting, in which finely

powdered metallic materials are selectively

melted by applying a laser beam in an inert

gas atmosphere. The mechanical properties

correspond by and large to those of the basic

materials. Particle sizes are selected subject to

layer thickness and surface quality.

The installation space for the parts that can

be produced is limited.

FDM – Fuse Disposition Modeling

This process works on a principle similar to

that of a hot-melt glue gun: using a nozzle

that moves three-dimensionally in an open

space, melted thermoplastic polymers are

sprayed on layer by layer, and built up to

produce a workpiece. The introduction of

reinforcing fibres, e.g. in the form of attached

continuous filaments, produces material

properties suitable for structurally relevant

components. The process is still undergoing

development. Further advantages of the

process are the component dimensions that

can be produced (range of the robot arm /

additional mobile workpiece) and the

possibility of being able to use bio-polymeric

materials instead of petroleum-based or

biologically degradable polymers. This would

supply additional potential for sustainable

production.

Particularly promising additive manufacturing processes have been identified and their

technological effects examined as part of an intensive technology analysis carried out by

EDAG experts and leading authorities in the field of additive manufacturing.

During this think tank, it very quickly became clear that additive manufacturing processes

offer considerably more potential than current restrictions in the field of rapid prototyping.

For details of the technology roadmap and the other processes, see edition 1/14 of EDAG Insights

The following diagram shows an assessment of the processes in the form of a technology roadmap up to 2045.

Different technological leaps (so-called booster potential) were recorded and analysed, to assess the extent to

which they might contribute to the generation of larger vehicle parts. Overall, metal-based SLM and

thermoplastic-based FDM looked to be particularly interesting and promising.

6EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON

THE EDAG ROADMAP:THE EVOLUTION OF ADDITIVE MANUFACTURING IN THE COURSE OF THE NEXT DECADES

RoADMAP ADDITIVE MANUFACTURING

2015 2025 2035 2045

FDM FusE DEPosItIon MoDElInG

Principle: melted thermoplastic polymers are sprayed on and built up layer by layer, using a nozzle that moves three-dimensionally in an open space.

The inclusion of reinforcing fibres is still currently being researched (3D fibre printer).

slM Selective laSer Melting

Principle: electron beam melting: Powdered metallic materials are locally laser remelted under inert gas.

By and large, mechanical properties conform with the basic materials.

Particle sizes are selected subject to layer thickness and surface quality.

sls sElECtIvE lAsER sIntERInG

Principle: powdered thermoplastic materials are laser sintered layer by layer in an inert gas atmosphere.

Mechanical properties are below those of injection moulding.

slA stEREo lIthoGRAPhy

Prinziple: selective polymerisation of fluids by laser (epoxy resins).

A classic rapid prototyping process since the 1990s.

As a rule. material properties are geared to model building materials.

3DP 3D PRIntInG

Principle: solid materials are bound together layer by layer, using suitable bonding agents.

Subsequent treatment is carried out to define the properties of the workpiece.

Simultaneous printing of plastics in various degrees of hardness and colours.

Booster potential FDM

High performance thermoplastics

Booster potential 3DP

Subsequent treatment processes Optimisation of system of bonding agents for solid materials In situ bonding agents Portal instead of printer

Booster potential SLM

Customised alloys Multi-beam/scanner Weight – moulding flask


Alloy developments Scale-up


Biopolymers Optimisation of fibre matrix Multi-jet


Aligned endless fibres with high band width Plasticised material feed Robotics


Reactive chemistry

Booster potential SLS

Fibre reinforcementBooster potential SLS

Optimisation of matrix materials

Booster potential SLS

Multi-beam/scanner Scale-up


Consumer hype


Catalytic subsequent treatment

Booster potential SLA

Integration of fibres in 2D


Integration of semi-finished products Portal instead of a chamber

MATERIAL RANGE

ECOLOGICAL PERFORMANCE

PRODUCTION COSTS

STRUCTURAL RELEVANCE

COMPONENT SIzE

PROCESS SPEED

PRECISIONTOLERANCE COMPLEXITY

BATCH SIzE

EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 7

With „EDAG Genesis“, our exhibit at the 2014

Geneva Show, we provided a visionary outlook

for what might well be the next industrial revolu-

tion in automotive development and production.

The „EDAG GENESIS“ can be seen as a symbol

of the new freedoms and challenges in design,

development and production that additive ma-

nufacturing processes will open up to designers

and engineers. The structure is based on the

bionic patterns of a turtle, which has a shell that

provides protection and cushioning and is part

of the animal‘s skeleton. The shell is similar to

a sandwich component, with fine, inlying bone

structures that give the shell its strength and

stability. This concept is reflected in the exhibit.

The skeleton can be seen as a metaphor; in this

case, it does not form part of a musculoskeletal

system, but instead provides extra passenger

safety. The framework calls to mind a naturally

developed skeletal frame, the form and structure

of which should make one thing perfectly clear:

these organic structures cannot be produced

using conventional tools!

”EDAG GENESIS“ WAS ONLY THE FIRST STEP

Although the turtle had millions of years to

develop to suit its needs and, for instance, perfect

its „passenger safety system“, man is still theo-

retically at the very beginning of a possible para-

digm shift. The traditional rules of design, with

restrictions caused by production, will play only

a very minor role in additive manufacturing, and

the tried and tested construction methods of

nature can also be applied in a genuine series

production situation, which was unconceivable

in the past. Additive manufacturing enables

parts to be designed so that they are load-

specific, multi-functional and bionic, while

ensuring ideal (or „topologically optimised“) wall

thickness and outstanding material properties.

Working directly from the data models, tool-free,

highly flexible production is possible.

In 2014, the world‘s trade and economic press

picked up on the EDAG Genesis and made it a

subject of discussion. An intensive dialogue also

sprang up between vehicle manufacturers, sup-

pliers, manufacturers of semi-finished products,

research institutes, material suppliers, additive

manufacturing equipment manufacturers and

the EDAG experts. The sector was made aware

of these new and revolutionary concepts. Work

is currently being carried out on practical uses

for the impulses referred to.



EDAG LIGHT COCOON: THE STATEMENTFOR FUTURE LIGHTWEIGHT CONSTRUCTION


We are working on the assumption that it will

take some 10 years for the vehicle to be realised

in about 2025. The core idea of the „EDAG Light

Cocoon“ concept is not to regard the body as

a closed surface. Instead, an approach was

adopted in which material was only actually

used in areas where it was necessary for

function, safety and stiffness. This means that

the sheet metal surfaces that typically make up

the outer skin of a vehicle were broken up.

The ideal geometrical structure was validated by

our CAE team, to ensure compliance with the

basic requirements of the automotive industry.

Specially for this purpose, existing calculating

methods needed to be adjusted or new ones

developed in advance, to reduce the structure on

load paths (the paths that loads follow as they

pass through a component). The result:

the „EDAG Light Cocoon“ presents the same

kind of stable, branch-like load bearing structure

that can be seen in nature. Despite the fact that

less material has been used, all requirements

imposed on structurally relevant components

are met.

EDAG LIGHT COCOON: THE STATEMENTFOR FUTURE LIGHTWEIGHT CONSTRUCTION

Following the „EDAG Genesis“ vehicle sculpture, we have expanded the vision of a bionically inspired body structure. In doing so, we are pursuing sustainable approaches – as demonstrated by nature: lightweight, efficient, and without any waste.


Simulation on the basis of a series bonnet

To first of all quantify and then verify the light-

weight potential of a bionically designed

structure, this approach was previously used, for

example, in the design of the bonnet of a

production vehicle, and then calculated. The

point of the calculations was to confirm require-

ments, e.g. with regard to torsional and flexural

stiffness, and also to pedestrian protection.

The results of the topological CAE calculation

simulation are promising: a vehicle‘s bonnet is an

extremely complex component which is subject

to both static and dynamic load cases. In order

to withstand the static loads, there is a very

simple geometry for the structure of the

bonnet, see diagram in upper left-hand corner.

This structure is not able to withstand the

dynamic load cases, e.g. to meet head impact

specifications, as the hole pattern is too open.

The diagram in the upper right-hand corner

shows the geometry that will meet the

requirements of the head impact test.

The calculation results confirmed two things:

that the basic stability requirements were met,

and that a weight saving of approx. 25 % was

achieved with this bonnet (achieved in an

exemplary fashion by using aluminium profiles

of different thicknesses).

Bonnet A, Source EDAG Bonnet B, Source EDAG


Fabric outer skin

To protect the vehicle from the effects of the

weather in spite of its open structure, but still

meet aerodynamic principles, an additional

fabric covering was designed for the EDAG Light

Cocoon.

The leaf of a plant served as the blueprint for the

innovative design of the body shell. Just like the

structure of a leaf, which has a lightweight outer

skin stretched over it, a lightweight protective

skin covers the EDAG Light Cocoon – though in

this case, it is made of a textile fabric.

In Jack Wolfskin, outdoor specialists, the ideal

project partner was found to supply a tried

and tested stretch fabric that is also extremely

weatherproof, to serve as the new outer body

skin. TEXAPORE SOFTSHELL O2+ is a triple-

layered polyester jersey fabric, which is extremely

lightweight, durable and watertight.

The material‘s excellent elasticity is what

qualifies it for the bionic structure of the EDAG

Light Cocoon, as provides a perfect fit. Weighing

no more than 19 g/m², the Jack Wolfskin materials

support maximum lightweight design requirements

with minimum weight.

The conscious separation of the structure and

outer skin surface makes it possible for the first

time ever to consider the use of textile materials

for the exterior, as these do not have any

structural tasks to fulfil. Thanks to an LED back

light concept, the interaction between light,

structure and fabric created attractive – and

above all – innovative vehicle aesthetics. Apart

from the ornamental effect, this also makes a

tactile experience possible


that our present computer-based software for

the styling, development, design, calculation and

production phases is not in line with the new

processes.

However, this will give rise to completely

different questions. If the design data, which will

then be restricted to the surface data of the

products and their spare parts, is made available

on the Internet – simply scanning the surface of

a product will suffice – then the question of in-

tellectual property rights will arise. We are alrea-

dy experiencing similar problems in other fields,

e.g. the music, film and photographic industries.

It is therefore evident that, although there will

be a great many chances for new business

models (e.g. online 3D print shops, integrated

3D scanner software in smartphones), there will

also be many risks for any companies that fail

to consider the general context.

Wer are on the threshold of a possible paradigm

shift for which nobody is currenntly prepared,

so it remains to be seen how we organize and

orientate ourselves in the relevant areas, and

which industry will play the leading role in

establishing additive manufacturing processes in

series production.

Production will first of all become waste-free and

resource-saving, and, with the thermoplastic

processes, we will also later be able to draw on

nature-based materials, the biopolymers. We will

then be able to produce products on-demand –

without major warehousing or transport costs,

including the effects they have on the environ-

ment – since these new factories will be decen-

tralised, which will mean fewer resources, less

complexity and lower investment. The same

will then also apply to the procurement and

production of spare parts, and the provision and

servicing of tools beyond the production period.

In this case, the networking of development and

production in the sense of the „smart factory“

would be not so much a means to an end as

absolutely essential.

These new production processes will also have

an effect on our development processes, as

all the familiar restrictions previously linked to

production-oriented development will become

obsolete. Suddenly, it is possible to produce

anything! The new processes enable us to +6

reproduce nature, and bring us one step closer

to adapting bionic thought patterns. It will,

however, be necessary to introduce our future

designers and engineers to these ideas and train

them accordingly, and we will come to realise

SOCIAL RELEVANCE AND SUSTAINABILITY

should it prove possible to implement processes and technologies of this type in series

production in the foreseeable future, this will have far-reaching effects on our society, and may

help to preserve our ecosystem.


THE CONCEPT IN DETAILS


Motors of this type are already available, and the

necessary amount of installation space has been

taken into account in the overall vehicle package.

The energy is fed to the motor by a T-shaped

battery pack. The layout selected guarantees

that the centre of gravity is low and positioned

towards the rear, and also meets the styling

department‘s requirements for a very sporty

vehicle line. In addition, this layout also means

that a large-volume hydrogen tank can be used

without any problem.

According to the basic idea of constructing the

EDAG Light Cocoon as a two-seater sports car for

the year 2025, an overall length of almost 4.2 m

and a wheelbase of 2.5 m were defined. This puts

the car in the same vehicle class as an Audi TT or

a BMW Z4. Due to the car‘s bionic, topological

optimisation, its overall weight is 1,250 kg. Due

to the central electric motor, we have achieved an

acceleration rate of 0 to 100 km/h in about

6 seconds.

Drive concept and package

To accommodate the idea of sustainability in the

drive concept, too, the EDAG Light Cocoon has

been designed as a fully electric vehicle. At its

heart, there is to be a 185 kW central electric

motor which will drive the rear axle, and has a

torque of 380 Nm. More than enough power

for a fast overtaking manoeuvre in a car with an

overall weight of 1250 kg.

DETAILS

Class: Sports car, two-Seater Lithium ion battery: 59 kWh Target weight: 1,250 kg Consumption over 100 km: optimal 13 – max. 25 kWh Range: approx. 350 km Motor: Hybrid synchronous motor 0 – 100 km/h: approx. 6 sec. 185 kW Vmax: 150 km/h Torque: 380 Nm

Control electronics

Battery pack


When selecting a suitable energy storage system,

the first thing to do was to anticipate future

technological developments. It is reasonable to

assume, and this is in line with the NPE roadmap

(National Platform for Electric mobility), that there

will not be any technological disruption or tech-

nology changes to battery storage (to Li-air/Li-S

batteries) until after 2025. Until such time, the

evolutionary development of the safety, energy

density and, above all else, price of existing Li-ion

technology is expected. Current advances give rise

to expectations that capacity will soon increase

by around 50 %, while volume and weight will

remain unchanged. Our estimates for the Light

Cocoon are based on the assumption that capa-

city at system level will increase by a conservative

40 % with conventional technology, which seems

very likely to happen by 2025.

If we look at the multi-cell batteries in standard

use today, they already produce volumes of

energy between 23 and 43 kWh and ranges from

180 to 335 km. As we see it, the 40 % evolutio-

nary development that we are assuming will be

sufficient to ensure reliable ranges beyond the

350 km mark from 2025 onwards.

We are assuming that the EDAG Light Cocoon

will have a consumption value between 12.9 and

25 kWh/100 km, depending on

luxury features such as air conditioning or an

infotainment system. A value that is geared to

factory specifications for current electric vehicles,

and already realises the savings potential,

particularly with the ancillary equipment.

For a desired range of 350 km, we assume that

an energy storage system capable of producing

an energy quantity of 59 kWh will be required.

Since we anticipate that a reliable quick charging

infrastructure will have been established by 2025,

a range of 350 km will be sufficient to allow the

vehicle to be used anywhere. The vehicle will

move intelligently within the power supply

system. Short breaks that will have to be taken

to top up the car‘s energy supplies will not in any

way impair its use, despite the limited amount of

energy available.

In special application scenarios (e.g. if it is being

used exclusively for long distances or in countries

which do not have a charging infrastructure), a

range extender might still be advisable.

Control electronics

Battery pack

Range Extender

Hydrogen Storage


short supply in an electric vehicle. It must also be

treated as a scarce commodity by the auxiliary

equipment. Good energy management will be

essential for future vehicles. Important factors

such as range, performance and comfort are

decided here, and so, along with the develop-

ment of energy storage systems, make a decisive

contribution to the breakthrough of renewable

energies. Here, too, the EDAG Light Cocoon

profited from EDAG‘s engineering competence

in the field of power electronics and distribution,

energy management and battery systems.

From today‘s point of view, conventional internal

combustion engines are generally ideal for use

as range extenders, to vary the battery size and

therefore the cost. Unfortunately, this measure

does away with the advantages of a fully elec-

tric vehicle (CO2 neutrality, low noise emissions,

etc.). For this reason, we decided to install a

revolutionary, zero-emission range extender

which is based on fuel cell technology in the

EDAG Light Cocoon. Fuel cell systems are

currently undergoing rapid technological de-

velopment, and offer great potential for the

efficient generation of constant energy.

In the EDAG Light Cocoon package, the

position defined for the optional hydrogen tank

is the area in front of the rear axle – the safest

place with a view to rear and side collisions.

The battery volume is reduced to accommodate

the hydrogen tank.

In the first calculations carried out using this

approach, the EDAG experts achieved a range of

more than 500 km. Energy management proved

to be a further challenge. Energy is in particularly


To bring about this optical highlight, a number

of technical challenges first had to be solved.

As the requirements were for the vehicle‘s

spoiler to remain inflexible in its movement, for

the cover plate to be bent and also the length

of the spoiler‘s edge to be adjusted, a material

capable of meeting these high standards had to

be found.

What the EDAG experts found was a special

PU material able to withstand the tensile stress

and deformation. With the help of two infinitely

variable servo motors, the spoiler can be electro-

mechanically adjusted to suit the vehicle‘s speed.

Fully extended, the servo is an impressive 7 cm

high. The airflow around the rear end of the car

is ideal, providing the necessary down force.

Seamless mobility:

The Light Cocoon‘s spoiler

Apart from offering a high degree of lightweight

potential, the use of a flexible textile fabric also

opens up other chances. Moving components

can be covered just as easily as the rest of the

vehicle. This idea was first used on the Light

Cocoon‘s mobile spoiler. Conventional spoilers

rely on mobile components. A concertina wall

is generally used to optically integrate this wing

into the vehicle. Furthermore, in its retracted

state, it creates a very pronounced visual effect.

Due to the hi-tech fabric used on the Light

Cocoon, when the spoiler is extended, this is

tantamount to a geometrical adjustment of

the vehicle body. The fabric performs every

movement required of it. There are no joins to

detract from the vehicle‘s appearance, no

extendable components to generate down force

due to the airflow.

approx. 70 mmFabric stretched

Fabric


can, for instance make configurations and

settings offline, and then activate them in the

car. His data is always available without being

directly dependent on the car. Also, the cloud-

based mapping of some of the functions can

transfer computing power away from the car.

From the manufacturer‘s point of view, there are

also additional opportunities for ensuring brand

loyalty. Once acquired, functions can be used in

compatible vehicles of the same brand. Com-

pared with the high cost involved if the brand

is changed, the low cost of changing within the

same vehicle brand could make this lock-in

effect very attractive to customers.

On account of the far greater transparency in

the pricing of features, however, the manufac-

turers will in the future have to make the added

value of these functions perfectly clear. It will

then be possible for the rising cost of software

development, for instance, to be offered and

financed separately. And the manufacturers can

draw on EDAG‘s know-how when it comes to

this task.

Personalisation via accounts

Car owners want to personalise their vehicles.

That does, however, mean more than just

ordering a few extras from the manufacturer‘s

list of accessories. We are already familiar with

the practice of creating our own ideal mobile

phone profiles by means of optional settings and

apps, and customers want to be able to make

use of a similar range of functions in their cars

in the future. Possible vehicle settings might be

seat adjustments, media play lists, display

configurations, themes, but also a preferred

chasis setting. With the EDAG Light Cocoon,

a further dimension is added. The innovative

exterior lighting technology enables the custo-

mer to present his vehicle in any lighting set-up

imaginable.

With the EDAG vehicle, the concept of persona-

lisation is taken one step further: features are no

longer defined in the vehicle; instead, they are

linked to a personal account. This makes the

account-related activation of selected vehicle

functions possible. This idea provides the

customer with numerous advantages: the driver

Possible personalisation in the interior of the eDag light cocoon. the use of fabric as a very flexible projection surface in the

interior offers a high degree of freedom in the adjustment of the controls via a personal account.

EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON

20

bile production. As an engineering company,

we see it as our task to make sure that we are

today already working on technologies of the

future and completely new approaches to

vehicle development. When it comes down to it,

working on concept car projects like the „EDAG

Light Cocoon“‘ enables us to build up additional

competencies within our company, while at the

same time also encouraging people to think

outside the box and tread new paths in order to

achieve the best possible technical solutions.

People like us, who develop the cars of tomorrow,

must always keep their focus on the day after

tomorrow.

There are already plans to present a number of

selected, structurally relevant components using

different materials and additive manufacturing

methods at the IAA 2015 in Frankfurt.

In addition to this, we will also continue to press

ahead with subjects related to connecting the

vehicle up to the Energy Internet, and to the

personalised car account.

With the futuristic concept of our „EDAG Light

Cocoon“, we want to make a conscious con-

tribution to stimulating the discussion about the

future of lightweight construction and automo-

CONCLUSION

We will continue to keep a close watch on the evolution of additive manufacturing.

the target: to develop practicable and valid applications for use in component development

and production.

Copyright 2015

EDAG Engineering GmbH

Kreuzberger Ring 40

65205 Wiesbaden

Germany

Reproduction without written permission is completely forbidden.

EDAG INSIGHTS

WOULD YOU LIKE TO KNOW MORE ABOUT BIONIC DESIGN AND THE EDAG LIGHT COCOON? THEN ASK US.

Johannes Barckmann, EDAG,

Head of Design Studio

Contact:

Tel.: +49 661 6000-610

[email protected]

Heiko Herchet, EDAG,

Project manager, Electric Mobility

Contact:

Tel.: +49 661 6000-9098

[email protected]

AUTHORS OF THIS EDITION

Johannes Barckmann, Heiko Herchet, Michael Pollner

Documents

EDAG INSIGHTS 1/15...EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 2 Inspired by nature. Additively manufactured. And the ultimate in lightweight design. The ”EDAG Light Cocoon“ is a