Future Trends in Composites - · PDF fileFuture Trends in Composites Enrique Garcia –Chief Technology Officer Paul Gallen –Automotive Sector Lead Leah Rider ... • Joining & “unjoining

© National Composites Centre. All rights reserved. Confidential and proprietary document. AD-TMP-034 v9

Presented by

Future Trends in Composites

Enrique Garcia – Chief Technology Officer

Paul Gallen – Automotive Sector Lead Leah Rider - Research Graduate


Delivery agent for the UK Composites Strategy

Open-access, industrial scale, Research, Development & Training facility

Led by industry, used by industry, and hosted by University of Bristol

Part of the High Value Manufacturing Catapult

The National Composites Centre (NCC)


Opportunities across all Sectors

CLF UK Opportunity Predictions 2015


The NCC Mission

To accelerate the growth of UK industrial output by

enabling design and manufacturing enterprises to deliver

winning solutions in the application of composites

TRL 1 TRL 5 TRL 6 TRL 7 TRL 8 TRL 9TRL 3TRL 2 TRL 4

Re

se

arc

h

Pro

du

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Basic & Applied

Research

Technology Feasibility,

Development & DemonstrationTechnology Launch &

Operations

Universities HVM Catapult Centres

Industry

NCC FocusAlign Research with Industry

needs

Technology

to Industry


The NCC provides

Multiple sector company engagement - OEM’s to SME’s

~175 NCC Expert Engineers & Technicians

Open-access

Confidentiality

Cross-sector

Collaboration

Design & simulation

Prototype manufacture

Process optimisation

Testing & inspection

Manufacturing & test

equipment

Industry training & skills

development


Presented by

The Opportunities for Affordable Automotive Composites

Paul Gallen


Automotive Sector Market Drivers

• The key driver for change is CO2 emissions regulations from 2020.

• Financial penalties (to OEMs) likely if average fleet emissions targets exceeded from 2020

• UK automotive sector strong in luxury, sports and niche segments with high vehicle CO2 emissions.

• Significant risk/opportunity for UK automotive sector. Opportunity for

composites

EU Fleet emissionsTarget 95g CO2/km 2020;

75g CO2/km 2025?

From 2019, EU penalty = €95 for every gramme per car emitting more than 95 g CO2/km

OEM producing 1M cars @ 100g CO2

could have €475M penalty


Automotive Sector – Why lightweight using composites?

• Weight saving – composites substituting for steel• Composites (thermoset, thermoplastic, CF and GF)

• Hybrid multi-material structural components.

• 100kg weight reduction = - 6 g CO2/km

• Cost saving – through life compared to steel• Component cost competitive with existing benchmark plus “on cost per kg saved”

• Requires reduction in cost of large tow carbon fibre to €8/kg

• Use of appropriate fibre reinforcement – GF or CF?

• Performance improvement• Improved vehicle dynamics

• Increased design freedom

• Reduced part count/ improved assembly

Weight saving is next step for CO2

reduction

Weight saving• reduces fuel consumption

• reduces CO2 emissions


Automotive Composites: How big is the opportunity?

Composites UK Conference 13 May 2014

2030 UK market for auto composites could be as high as £3.5bn, or as low as £1.5bn, depending on UK capability.

UK car production: 1.6m (2013), 2.0m (2017)

Global automotive production c.90m in 2017

‘by 2030 all cars will use 50- 500 kg of composites’

UKTI 2015


Automotive Sector Challenges

• Industrialisation• High volumes require Tier 1 supply chain participation

• Automated processes for high volume manufacture (<3 minute takt time)

• Customised preforms/ thermoplastic laminates to eliminate fibre waste

• Creating “pull” for Carbon Fibre cost reduction development and on-shoring

• Materials specs & standards

• Multi-material optimisation

• Improved CAE design, simulation & validation tools• Best practice adoption

• Training

2016 - 2020

• Co-ordinated UK collaborative programme needed for cross-industry participation

• Global competition means support is required for rapid UK delivery to prevent offshoring


Automotive Composites: Forecast Materials Demand

Composites Germany 2015

Many market studies indicate automotive requirement for Carbon Fibre will increase quickly from 2015 -2030

“Transport (Road & Rail)CAGR 7.2% (2014-19)”

Lucintel May 2014

This market is unlikely to use Aerospace grade Carbon Fibre


What can we lightweight?

Most OEMs develop in-house

High barriers for change – BIW line investment

Safety critical

Tier 1 sourced

Incremental change opportunities -

Tier 1 sourced

Incremental change opportunities

In-house and outsourced

CF panels luxury/sports

Move towards structural composite modules and systems

Tier 1 sourced

High existing use of polymers

CF Thermoset(HP-RTM,Compression moulding etc)

Hybrid multi-material

Hybrid multi-material

Hybrid multi-material• Pressing • HP-RTM

Fibre reinforced thermoplastics

Composite Technologies

Market factors


Lightweight Package by vehicle segment

OEMs will pay for lightweighting – depends upon vehicle type and market segment. They will pay penalties if they don’t!

Acceptable € on-cost/kg


Opportunity Summary

Supply chain readiness• 100k components pa by 2020• Efficient manufacturing• (< 3 minute takt time)• New material formats• Eliminate waste• Designed for manufacture

Repairability & replaceability• Design for repair and

replacement• Joining & “unjoining”• Recycling & LCA

“Standards”• Materials specs & standards• Multi-material optimisation• Improved capabilities and

widespread use of CAE design, simulation & validation tools

Repairability & replaceability• Pieec part cost

2020 onwardsPiece parts supplied at volume and at appropriate cost (not exceeding existing cost plus “on cost per kg saved”)

Short window of opportunity!


Presented by

Driving down weight:NCC delivering benefit

Leah Rider


High Pressure Resin Transfer Moulding

High Pressure Resin transfer moulding (HP-RTM)

Development of standard of resin transfer moulding

Produce parts within 3 minutes of closing the press

Developed for volume automotive parts

Currently pioneered by BMW (i3 and i8 models)


High Pressure Resin Transfer Moulding

Place preform

into mouldStart cycle

Draw vacuum in

mould

Inject at high

pressure

Cure component

Eject from mould


Capability

Schuler 3600T Press

3.6 x 2.4m platens

100T max. tool weight

36,000kN pressing force

1,000mm/s closing speed

PEI 1100T Press

1.8 x 1.3m platens


11,000kN pressing force

800mm/s closing speed

Secondary platens heat up to 450°C


Capability

KraussMaffei HP-RTM Injection Kit

Combined epoxy/PU system

Internal release agent

Injection pressures up to 120bar

Pallet mounted for flexibility between

presses

Hedin Die Cart and Die Splitter


Used to accept tool deliveries and carry out

conditioning exercises

Compatible with both presses


HP-RTM Trials at the NCC

Range of customers from the automotive

supply chain at the NCC.

Tooling:

Flat panels

Omega panels

Antenna panels

Snap cure resin systems

Trials include:

HP-RTM robust process control

investigation to account for variations in

preforms

Use of recycled carbon fibre preforms in

the HP-RTM process


High Volume Manufacturing at the NCC

What can we offer:

Optimization of component design

Design for Manufacturing

Design for Inspection (in-process

monitoring)

Manufacturing Process Simulation

Material selection

Life cycle analysis

Process development and optimisation

Process trials (CpK)

Full scale prototype

Secure, independent facility

Knowledge Transfer

Training


New Opportunities for Composites

Thank you for your attention

Questions?


© National Composites Centre (NCC). All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of NCC. No

intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the

express written consent of NCC. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute

an offer. They are based on the mentioned assumptions and are expressed in good faith.

© National Composites Centre (NCC). All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of NCC. No

intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the

express written consent of NCC. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute

an offer. They are based on the mentioned assumptions and are expressed in good faith.

www.nccuk.com

0117 3707 600

[email protected]

@NCCUKinfo

Documents

Future Trends in Composites - · PDF fileFuture Trends in Composites Enrique Garcia –Chief Technology Officer Paul Gallen –Automotive Sector Lead Leah Rider ... • Joining & “unjoining