1. High Volume Manufacturing of Composites June 2014 Tobias Potyra Fraunhofer Project Centre @ Western tobias.potyra@ict.fraunhofer.de

2. Motivation Motivation for Light-weight design Alternative drive train concepts: fuel cells, hybrid and E-propulsion 800 19801985199019952000 2005 2010 1200 1000 Weight [kg] + 400 kg +50 % + 100 to 300 kg 1400 EU regulation CO 2 emissions < 120g/km EU regulation CO 2 emissions < 120g/km EU regulation CO 2 emissions < 120g/km Weight increase of typical medium-class vehicle since 1970. Implementation of CAFE regulation. Reduction of consumption and emissions through lighter structures. Improvement of passive and active safety and product attractiveness through functional design. For commercial vehicles: increased payload. Lightweight design requires quality controlled, high-volume manufacturing processes for composites.

3. Lightweight Potential of Composites

4. Characteristics of Composite Materials Advantages of Composites Low density High weight-specific strength and stiffness Good damping Very good failure behavior Anisotropic properties Very low thermal expansion parallel to fibers Dependent on application: –Low thermal conductivity –Low electric conductivity Very good corrosion resistance Disadvantages of composites Mostly lower temperature resistant than metals Particular knowledge required for proper design Higher effort for quality assurance Oftentimes high material cost More difficult to realize automation Not yet established industrial processes

5. Overcoming the shortcomings by Transferring a holistic approach to mass production requires competences across the entire value chain Architecture Design Material technology Component manufacture Bonding, joining technology Testing Verification Use Light-weight strategy Integration of functions Modelling Simulation Manufacturing Processes Reliability

6. Overcoming the shortcomings by Holistic consideration of materials, production processes and methods leads to new construction methods in multi-material design Methods ProductionMaterials Multi material design

7. Manufacturing Technologies METHODS – PRODUCTION – MATERIALS Automated, high-volume production chains Composite technologies Long-fiber reinforced thermosets (SMC + PUR) High Performance Composites RTM/ HP RTM Long-fiber reinforced thermoplastics (LFT) CAx methods for light weight multi-material design

8. House of Production Part Requirements / Specification / VOC Successful Part Production Material Selection Selection of the Manufacturing Process Design Internal / External Knowledge Economics

9. House of Production with incomplete pillar

10. Fraunhofer Project Centre for Composites Research at Western University FPC @ Western A joint venture between: Western University, London, Ontario, Canada And Fraunhofer Gesellschaft, Munich, Germany & Institute for Chemical Technology (ICT), Pfinztal, Germany Contact: tobias.potyra@ict.fraunhofer.detobias.potyra@ict.fraunhofer.de www.eng.uwo.ca/fraunhofer

11. Twin Regions Joint Expertise for Local Demands Both entities, being situated in the heart of automotive areas will jointly work on composite technologies adapted to the local demands of each region’s industry. The activities of both research entities will utilize and increase the expertise to accelerate composite innovations as lightweight solutions. Transatlantic Cooperation

12. Applied Research with Industry Bridging the gap in the knowledge chain.  Realization of industrial processes  Application of developed innovative processes  Optimization of existing processes and materials  Realization of industrial processes  Application of developed innovative processes  Optimization of existing processes and materials  Basic research on fiber matrix phenomena  Simulation and Design  Investigation of fundamental interests collaboration with industry collaboration with FPC@Western collaboration With universities

13. Benefits of collaborating with FPC Research and Development goals are addressed in a holistic way so that solutions take the whole value chain into account from the first idea over material development to manufacturing issues up to the final part and the application of the part Material Process Methods Part

14. Full industrial scale shop floor capable for carbon fiber composites Globally first LFT-D line for processing of carbon fibers Globally first HP RTM line for processing of unsaturated polyester resins, epoxy resins and polyurethane resins Globally first injection moulding machine for direct heating and co- moulding of local reinforcements with foamed polymers North America‘s first Direct SMC line Applied Research in Industrial Scale Technological Highlights at FPC

15. Thank you very much for your attention!