1. Faurecia Interior Systems Less is More
Brett Schnur
Innovation Project Leader

2. CCB: Cross Car Beam NAFILean Lignolite+ & NFPP+ AGENDA
Natural Fiber for Lean Design Injection
Lignolite+ & NFPP+

3. Cross Car Beam

4. CROSS CAR BEAM - The Key Figures
COMMON WEIGHT & PERCENT OF VEHICLE INTERIOR
Representing 33% of the instrument panel weight, the CCB is the heaviest component.

5. CROSS CAR BEAM - Innovation
Faurecia is approaching the cross-beam challenge from three directions that are driven by a “Less is More” perspective.

6. CROSS CAR BEAM - Faurecia’s Plug & Play
The Plug & Play Steel CBB offers a 5% reduction in weight.

7. CROSS CAR BEAM - Faurecia’s Plug & Play
ABOUT THE PLUG & PLAY
Variable thickness (from 1 to 2 mm)
Variable diameter (from Ø40 to Ø80)
Variable Inertia

8. CROSS CAR BEAM - Faurecia’s Hybrid CCB
The Hybrid CCB offers weight savings of up to 20%.
Sheet Molding Compound (SMC)
Steel from Plug & Play Technology

9. CROSS CAR BEAM - Faurecia’s Composite CCB
The Composite CCB leads to weight savings of more than 40%.

10. CROSS CAR BEAM - Summary
PLUG & PLAY CCB
WEIGHT SAVINGS
Full steel CCB assembly using Cold Metal Transfer Welding
Up to -5%
2015
HYBRID CCB
Up to -20%
Combines 3D SMC attachment brackets to Plug & Play steel technologies
2016
COMPOSITE CCB
Minimum
-40%
2018
Combines multiple technologies for maximum weight savings

11. NAFILean

12. AUTOMOTIVE PERFORMANCE MATERIALS
Natural fiber specialist headquartered in France
Automotive injection molding expert

13. COMPETITIVE ADVANTAGES
NAFILean
ABOUT NAFILEAN
Polypropylene +20% natural fiber compound to substitute for PE-MD20 and ABS
Injection molding of covered DP trim parts, IP top cover, defrost and closure ducts
COMPETITIVE ADVANTAGES
Lightweight concept: up to -25% for door panel and -20% for instrument panel, depending on architecture
Green material with better environmental impact / CO2 balance: -20 to -25% Life Cycle Assessment

14. Natural Fibers for Lean Design Injection
DEVELOPMENT OF FAURECIA’S PP + NATURAL FIBERS COMPOUND
In production on Peugeot 308 door panel
Validated at multiple OEMs
One patent

15. DOOR PANEL INSTRUMENT PANEL NAFILean - Validated Parts 25% 20% 25%
TOP ROLLS
WEIGHT SAVED
25%
TOP PAD
WEIGHT SAVED
20%
2-3.5mm thick
Density & thickness
2-2.5mm thick
BOLSTER / INSERT
WEIGHT SAVED
25%
2-2.5mm thick
20-25%
DUCTS
WEIGHT SAVED
2mm thick
12.5%
DOOR PANEL CARRIERS
WEIGHT SAVED
2-2.5mm thick
Direct drop in

16. NAFILean - Interior Validation
PROCESS
Injection
Back injection
Weakening by laser (air bag function)
TPO Thermo-covering
Foam in place
Vibration and U.S. Welding
Fastening
Adheres to Design Standards
PRODUCT VALIDATION
Dimensional behavior on instrument panel
Sun load 120°C for 500hrs
Climatic aging
Air bag deployment
Head impact
NVH – CAE Comparison
Foaming
Side impact
Repeated load durability
Often Better Than Production

17. Compression-Molded Mat Technologies

18. NATURAL FIBER MAT
TWO TYPES OF IMPROVED LIGHTWEIGHT COMPRESSION-MOLDED MATERIALS
LignoLite+
NFPP+ (Natural Fiber Polypropylene)

19. LIGNOLITE+ Door Panel Application ABOUT LIGNOLITE+
Lightweight door panel carriers made from Wood Fiber Composites (WFC)
Based on hot press technology
Made up of 85% natural fibers, bio-based material, green and renewable material
Contributes to weight reduction—up to 25% savings vs. currently used lightweight solutions
Up to 45% savings vs. injected carriers, resulting in CO2 reduction and integration of renewable materials

20. LIGNOLITE+ Tailored to Your Application Resin 1 Resin 2 Resin 3
Wood fibers
Other fibers
LignoLite+
LignoLite
Lignoprop
Lignoflex ECO
Lignotock+
Lignotock
Resin 1
Resin 2
Resin 3
Wood Fibers
Bonding Fiber 1
Bonding Fiber 2
Other Fibers
Wax

21. NFPP+ Door Panel Application Common industrial mat weight = 1450 gsm
1250gsm mat available
Weight savings of 14% (vs. common mat)

22. CCB:Cross Car Beam NAFILean Lignolite+ & NFPP+ CONCLUSION
Weight Savings : up to 40%
Validated to Multiple OEM Specs
Weight Savings : DP = Up to 25%
IP = Up to 20%
NAFILean
Natural Fiber for Lean Design Injection
Lignolite+ & NFPP+
Weight Savings of 45% vs. Standard Injection Materials