Company Private and Confidential

From hours per part to parts per hour

Who’s The Competition?

AISI Mission

The American Iron and Steel Institute’s Mission is

to influence public policy, educate and shape

public opinion in support of a strong,

sustainable U.S. and North American steel

industry committed to manufacturing products

that meet society’s needs.

The Aluminum Association represents U.S. and

foreign-based companies and their suppliers

throughout the value chain, from primary

production to value added products to

recycling. The Association is the industry’s leading

voice, providing global standards, business

intelligence, sustainability research and industry

expertise to member companies, policymakers

and the general public.

Committed

Organized

Focused

Effective

Composites

AutomotiveComposites

No Singular Voice / Message

Evolve from R&D to Production

Plaques

Hat Sections

Real Parts – Not

Generic

<5 min Cycle

2010

Slow Cure Cycle - 90-120 mins

Thermally Inefficient

N2 Atmosphere

Low Volume Production

Autoclave

Fully Funded by Plasan

Proto C6 Roof Panel

Faster Cycle Time <20 mins

Thermal Efficiency

Oxygen Atomosphere

Out of Autoclave

Challenges of Launching Volume CFRP

No Existing North American Auto CFRP Infrastructure

Technology

People

Equipment

Tooling

Supply Chain

Pragmatic Innovation Was NEEDED

How to Accelerate from 40/day to 400/day?

Now the Mass Production

Consider Composites …

Cost effective

Rapid manufacturing

Predictable performance (CAE)

Scaleable – prototype to production

Durable

Good competent supply basePIL video

How to Accelerate from 400/day to 4000/day?

The Best of the Best are needed – Partnerships!

Partners

Hexion- Resin Technology

Fraunhofer (ICT/FPC) – Prototype facilities / equipment

Forward Engineering – Design / FEA analysis

ESI – mold flow / drape analysis

Alpex – Mold Tooling

Dieffenbacher / Kraus Maffei – equipment at

Fraunhofer

Sigmatex/Zoltek – Reinforcement Fabric

All with skin in the game – technology, resources and/or money

Advanced Tooling Solutions for Composites

Leading tooling specialist

Conception, design & manufacturing

Automotive & Aerospace industry

Office in Brighton, MI

Headquarter in Innsbruck, Austria

Deep process know-how

Excellent project handling

Continuous R&D

ISO 9001 and EN 9100 certified

ALPEX TECHNOLOGIES

ESI Group - Virtual Prototyping Solutions

Physics-based Simulation

Draping, Preforming & Thermoforming

Composite Manufacturing Simulation Automotive Customers

RTM KTM Front Splitter (Area of Excessive Fiber Shearing Shown)

Dieffenbacher - Business Unit Composites

Preform Center

Compress Lite Hydraulic Press

HP-RTM Production Line

■ Turn-key system supplier of complete production lines for the

manufacture of CFRP, LFT and SMC parts, based on compression

molding process

■ Family owned business since1873

■ Manufacturing operations in Germany, Canada and China

■ Expertise in HP-RTM lines incl. automated preforming, trimming,

pressing and post processing

Compression MoldingTechnologie CM

SMC

Sheet

Molding

Compound

D-SMCDirectSheet

MoldingCompound

LFT-DLong Fiber

ThermoplasticsDirect Process

GMTGlass Mat Reinforced

Thermoplastic

HD-RTM

High Pressure

Resin

Transfer

Molding

LWRTLightweightReinforced

Thermoplastic

Tailored LFT-DEndless

Fiber-ReinforcedThermoplastic WET Molding

HybridSteel/ CFRP

Fiber PlacementFiberforge

Company Private and Confidential

Lightweight portfolio covers the entire range of requirements

Plant technology for Thermoplastic and Thermoset composite

Injection Molding

Machinery

FiberForm / IMC

Automation solutions

&

robots

Reaction Process

Machinery

HP RTM / Wet Pressing

Source: BMW

Company Private and Confidential

• Widest range of conversion technology

• Innovative textile design and manufacture

• Dedicated R&D

• Lightweighting Centre of Excellence

• 2D & 3D fabrics

• Multidirectional fabrics

• Spread Tow fabrics

• Integrated pre-forming binders

• Global manufacturing presence

• Market sectors served include Aerospace,

Automotive, Construction, Defence,

Marine, Space, Sports and Leisure.

The World’s Leading

Independent Converter of

Carbon Fibre

Lightweighting Excellence

Key Design Decisions Summary

Design Discussions

Carry Over Hardware

Bondline Gap Management

Geometrical features

Similar to Current Mg frame

Modified features for HP RTM

Relaxed radii, notched latch area

Roof skin configuration: Current roof skin

Opportunity for on-line painting

Designed for Mag - A BIG Challenge

Carry Over Hardware

Hardware attachment considerations

Carry over hardware: handles, latches, pins, latch covers, seals, headliner

Similar appearance / space claim for current Mg frame

Geometrically not optimized for Carbon Fiber composite

Geometrical Features

Geometrical features

Similar to Current Mg frame

Modified features for HP RTM

Relaxed radii, notched latch area

Bondlines

Bondline

3mm gap target, relaxed to allow carryover hardware (headliner / seals) – 5 mm avg

Increased at front and rear to maintain same seal and sealing surfaces on vehicle

Bumped out seal features – lower cost integrated design

7.5 mm

3.0 mm 5.0 mm

7.5 mm

Bond gap thicknesses

Design Optimization

20+ configurations analyzed

Roding optimized design: lightest / most efficient use of CF / lowest cost Frame

FEA meets all stiffness, deformation, and natural frequency targets.

Build-up reinforcements enhance frame structural response at pins and latch points

Results Summary

Attribute Baseline (Mg

frame/CF skin)

CF frame / CF skin

Frame mass (kg) 2.74 1.3

Skin mass (kg) 1.66 1.66

Adhesive mass (kg) 0.91 0.45

Total assy (kg) 5.31 3.11

Fn – Assy (Hz) 34.5 ~34

Additional Opportunities

Optimized outer skin

Structural adhesive

Hardware / attachment buildups

* Natural frequency approximated between two assys with different outer skin layup configurations

53% Component

Mass Savings

<5 min Cycle

Time

Next Steps

OEM Validation Testing

Static

Dynamic

Limited Production Run

Automated Preforming

FPC London

Commercialization

Summary

Remember Who the Competition Is

Support Composites Growth

Real OEM Parts Demonstrate Capability

Haven’t isn’t the same as Can’t

Leverage Industry Resources - Partnerships

Supply Base

Consortiums

Grow the Talent Base