Laurent B. ChappuisLight Metal Consultants, LLC

§ Education§ Career highlights

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§ Born and educated in Switzerland§ Swiss Federal Institute of Technology, Lausanne (top 20 world universities ranking)

§ Graduated with the equivalent of an M.S. in Mechanical Engineering (1980)§ 2 majors:

§ Control systems, modeling and simulation§ Structural analysis, materials and FEA

§ Selected for a 1-year exchange program with Carnegie Mellon University, Pittsburg, USA (1977-78)

§ Emigrated to the United States in 1982§ M.S. Engineering Management, Wayne State University/Ford Motor Company (1999)

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§ 1979-1982: Self-employed consultant§ 1982-1985: Lamb Technicon Corp – Senior Simulation Engineer§ 1982-1986: MicroSystems Design Associates – VP Simulation§ 1986-2016: Ford Motor Company§ 2016-Present: Light Metal Consultants, LLC – President

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§ Chair, Stamping Modeling Development§ Technical Expert, Lightweight Stampings§ Supervisor, Aluminum Production Technology Implementation§ Supervisor, Aluminum Processing§ Supervisor, Stamping CAE & Global Chair, Stamping CAE Implementation§ Technical Expert, Lightweight Stampings for F-150

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§ 25 years as an Internal Consultant, in a global role§ Cross-functional, covering all aspects of aluminium sheet development

§ Design guidelines§ Materials§ CAE methods§ Processing guidelines§ Tooling standards§ Equipment selection & plant setup§ Commercial contracts

§ Also covered Advanced High Strength Steel (AHSS) from a forming and modeling point of view.

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§ Managed a 100+ cross-functional team (PD, Materials Engineering, Stamping Engineering, Closure Assembly, Paint, Purchasing, stamping plants, assembly plants, aluminium suppliers & prototype shops)

§ > $5,000,000 budget (1991 dollars)§ Styling & processing similar to steel§ By 1997, Ford US made > 1,500,000 assemblies/yr and consumed ~ 25,000 metric

tons of 6xxx aluminium sheet (~2/3 of the worldwide volume.) § Fully hemmed and adhesively bonded closures§ Long term contracts§ First scrap tolling contacts (CSP)§ 3 US patents

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§ Stamping Engineering Representative for original AIV project (1991-1993)§ Signed the print for every part of the vehicle§ Development of the aluminium feasibility guidelines

§ 2003 Jaguar XJ§ Feasibility support, both styling and part design § Stamping Tooling Development & Stamping CAE Lead (first 100% CAE led draw

development)

§ Aluminium Sheet Expert for every high level study between 2000-2009§ Investments§ Material supply

§ Invited Speaker at multiple international conferences on automotive aluminiumsheet

§ Session chair, European Aluminium Association meeting in 2006

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§ Aluminium Sheet Expert for the project from inception in 2009 to launch in 2014, and ongoing production through 2016

§ Architect of the aluminium sheet eco-system for F-150, led development of recycling centric material specifications

§ Feasibility support, styling and part design§ Bill of material development and analysis for PD, Purchasing, Finance, Stamping Engineering

& Plant Engineering§ Certified every shipment of metal until launch§ Launch of production at metal suppliers§ Education seminars for PD, Ford plants and Tier-1 suppliers§ 3 patents awarded and 3 pending

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§ Wrote and implemented the first production stamping FEA code at Ford in 1990§ Between 2002 & 2009, led the development of all stamping CAE methods used at Ford today

§ Standardized material database§ Standardized failure criteria for mild steel, HSS, AHSS and Aluminium§ NC ready draw beads§ Springback computation§ Die face compensation & morphing

§ Draw die tryout reduced to <8hrs and dimensionals within metal thickness at First Panel to Gage§ 4 Henry Ford Technology Awards (highest technology award at Ford), 2 CAE technology

achievement awards and 1 CAE excellence award§ SAE Henry Ford II Distinguished Award for Excellence in Automotive Engineering§ Multiple presentations at international conferences§ Panelist at IFU 2008, Stuttgart, Germany

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More than steel, aluminium requiries a system perspective:§ Styling and design guidelines are

different than steel§ Limited supply => need to secure supply

in advance§ Expensive => recycling is key to

program affordability§ Time & temperature dependent

properties affect logistics

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§ 25 years of aluminum design knowledge§ Developed the original design guidelines for JLR and Ford§ Developed the alloy selection strategy for BIW and closures for Ford§ Developed the material specifications strategy for Ford

§ Launched both the first and the highest volume stamped, rive-bonded aluminiumintensive vehicles (2003 Jaguar XJ and 2015 Ford F-150)

§ An unmatched system-understanding of all implications of aluminium in the automotive BIW design, manufacture, supply and recycling

§ 30 years of stamping CAE§ 30 years of aluminium production experience

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