Next Generation Composite Manufacturing Hannah Tew …...• The Next Generation Composite Manufacturing (CLSP) programme aims to support a globally competitive UK automotive composites

Next Generation Composite Manufacturing

(Composites Large Scale Project –CLSP)

Contact : [email protected]

Hannah TewPaul GallenHVM Catapult21st June 2018

HVM Catapult mission

The HVM Catapult is the catalystfor the future growth and success

of manufacturing in the UK.

HVM Catapult help accelerate new concepts tocommercial reality and thereby createa sustainable high value manufacturing

future for the country.

What we do

Drive growth of manufacturing

Help companies of all sizes incubate and develop new technologies to commercial reality

Take the risk outof innovation

Give business access to:

— World class open sourced equipment

— The UK’s best relevant research knowledge

— At elbow support from engineers, scientists, technicians

— An environment of collaboration andopen innovation• Cross sector• Cross technology• Whole supply chain• Even among direct competitors

AFRC

Nuclear AMRC

MTC

NCC

CPI

AMRC

WMG

HVM Catapult centres

Introduction and Background

• The Next Generation Composite Manufacturing (CLSP) programme aims to support a globally competitive UK automotive composites supply chain from 2020 onwards:

• To capture ongoing value

• To identify and link high productivity technologies with product opportunities

• Leverage cross-sector opportunities and support from significant market changes.

• High Value Manufacturing Catapult (HVM Catapult) is providing collaboration and co-ordination support

• Industrial Strategy Challenge Fund Wave 3 (April ‘18) identified as a funding source to deliver objectives

Implication of the Revolution in Future Mobility Trends

Connected Electric

Autonomous Shared

Weight increases

Drivers for Lightweighting in Transport

RangeCleaner –

emissions targets

Industrial opportunity

Performancedemands

Lightweighting

2016 2020 2025

VehicleMass

New contentNew features (self-steering, ADAS)

Legislation (small overlap crash)~ +5% increase per decade

Hybrid:+10% vs today

CHALLENGEAVERAGE weight reduction of

existing systems must be:10-15% per decade

CHALLENGETYPICAL on-cost not to exceed

£2.50 to £5 per kg of weight saved

Weight Challenge10-15% / decade

UK Automotive Lightweighting Opportunity

CHALLENGEEXISTING vehicle end of life recycling

target requires> 85% recyclability

Programme Mission – Composites in Automotive

Identifying, developing and transforming the UK supply chain for competitive high volume manufacturing of composites for automotive applications and allied markets.

Auto Council TARGET 2025AVERAGE weight reduction of existing

systems of 15%

ACG TARGET 2025TYPICAL on-cost not to exceed £5 per

kg of weight saved

ACG TARGET 2025EXISTING vehicle end of life recycling

> 85% recyclability

ACG TARGET 2025TYPICAL takt time 60s

Global automotive composite prediction (Persistence Market Research)

UK automotive composite prediction (DIT)

Upper

Lower

POTENTIAL MARKET IMPACT £3.5 bn p.a. by 2030

UK supply chain globally competitive

In place for window of opportunity

Lightweighting roadmaps for Automotive

Lightweighting in roadmaps for Aerospace

Project to Programme

Composites Large Scale Project

• Existing £4M project

• Lead by HVM Catapult

• Four centre collaboration

• Focus on High Efficiency Preforming

Next Generation Composite Manufacturing

• Extended £10M ++ project

• Lead by Industry

• 5 OEM’s, 40+ suppliers, 4 HVM Catapult centres

• Focus on supply chain transformation

19th July 2016

CLSP - the facts (so far…)

>30 engineers contributed to CLSP technical activities

4.5 year projectAug 2015 – March

2020

4 HVM Catapult Centres collaborating

~£100 M ISCF wave 3 EOI submitted

UK Composite Cluster developed

> £10 M of relevant CR&D activity across 4

centres

Senior stakeholders involved

BEIS, DIT, InnovateUK, APC, ATI

8 automotive OEMs engaged

• 1 academic paper• 5 academic conference

papers• 8 external conference and

workshop presentations

2 self generated bids submitted by SMEs in

cluster

Cross- sector engagement

(Aero and ATI)

£3.3 M of HVM Catapult funding

Intervention planning underway

International engagement in

progress7 Universities aligned

36 LoS from stakeholders for ISCF

wave 3 bid

Next Generation Composite Manufacturing Overview

• Technology “Pooling” of non IP-protected data and knowledge to accelerate development

• Enabling activities running in parallel and cross-cutting within the demonstrator work-streams:

• Design, modelling & simulation

• Automation

• Cost modelling

• Quality assurance

• Material characterisation

• Capability demonstrator components to showcase selected technologies in OEM relatable applications

• OEM & Tier 1 led scale up projects co-funded through APC to demonstrate the readiness level of the supply chain in manufacturing the demonstrator components at rate, cost and repeatability

CLSP Advisory Group

…….Potential for other OEMS (cross-sector) to join this group

*non-exhaustive list

Cost & Process modelling.

Automation, Digital Manuf. and rate increase support

Cluster support

Aspirations and Gaps understood

Technology matching

Demonstration of Capabilities(Prototypes, processes, supply chain, digital manufacturing and high value design)

“Pool” of competitive manufacturing

technologies and knowledge

Scaled Industrialisation

OEM & T1 specific projects

• Delive

£10M Challenge

£20M APC

EOI Summary: Next Generation Composites Manufacturing

OEM relevant generic demonstrator

components identified

Representative attributes derived:

VolumeCostRate

QualityWeight

Properties

Existing UK composites supply-chain

capabilities and capacity understood

Highly competitive value chains identified Up to £20M

Funding

UK Supply Chain Development

Technology Development

ComponentDevelopment

Early OEM Engagement

BRUNEL CHALLENGE & “MADE SMARTER”

Design & CAE tools advanced

Long-term high value capture, competitive and innovative UK manufacturing, adoption of productive technologies

OUTCOMES& BENEFITS

Demonstrator – Roof Structure

• Large window apertures

• Monolithic structure

• Variable thickness

• Channelled geometry

• Packaging constraints

• Conventional fixing strategy

• Integration of features – clips, brackets

• E-coating Temps 180C (30 mins)

• Size: ≈ 1.4 × 1.8 m

60 sec Takt time

95% Recyclable

Aim for Zero material waste produced

20-50% Lighter than benchmark

£5/kg weight saved on cost

Demonstrator – Floor Section

• Complex curvatures

• Variable thickness

• Sandwiched cores

• Flexural and torsional rigidity of the car

• Seat and seat-belt mounting points

• Integration of features – clips, brackets

• E-coating Temps 180C (30 mins)

• Size: ≈ 2.5 × 2.0 m

120 sec Takt time

95% Recyclable

20-50% Lighter than benchmark

£5/kg weight saved on cost

Demonstrator – Cross-Car Beam

• Multi-component structural member

• Bolt-in / glue-in

• Closed-section beam

• Geometrically complex end parts

• Conventional attachment strategy

• Crash management

• Tight tolerances

• Integration of features – clips, brackets

• E-coating Temps 180c (30 mins)

• Size: ≈ 1.5 m long

120 sec Takt time

95% Recyclable

20-50% Lighter than benchmark

£5/kg weight saved on cost

Demonstrator – Gearbox / E-motor Case

• Multi-material part

• Fine geometric tolerances

• Compatibility with a range of fluids

• High temperatures

• Dynamic loads

• Size: ≈ 0.5 × 0.3 × 0.3 m

120 sec Takt time

95% Recyclable

20-50% Lighter than benchmark

£5/kg weight saved on cost

HVM Catapult Capabilities – Reinforcement Architecture

HVM Catapult Capabilities – Preform and automation

HVM Catapult Capabilities - Consolidation

Programme Outcomes

• Secure ISCF funding support or equivalent for programme with APC and industry match.

• UK maintains global position in automotive composites, but with higher productivity supply chain delivering to OEM requirements.

• Improved GVA and local content to address “rules of origin” issues.

• Transformation of the UK automotive composites supply chain into globally competitive cluster.

• Pull through capacity for further improvements in materials science, intermediates, virtual engineering and processing.

Contact: [email protected] Our request to you• Get in touch if you are interested and are not

already engaged