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Yan Pugh-Jones Frederick Walker 1 Aston Martin DB11, GALM, Birmingham, 2017 2 DB11 – Project Mission

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Yan Pugh-Jones Frederick Walker 1 Aston Martin DB11, GALM, Birmingham, 2017 2 DB11 – Project Mission Yan Pugh-Jones Frederick Walker 1 Aston Martin DB11, GALM, Birmingham, 2017 2 DB11 – Project Mission Architecture Manufacturing Summary Aston Martin DB11, GALM, Birmingham, 2017 3 DB11 – Project Mission Second Century Plan 7 new models in 7 years Aston Martin DB11, GALM, Birmingham, 2017 4 DB11 – Project Mission VH Platform DB9 Vantage DBS Rapide Vanquish II Coupe Convertible Special Projects Aston Martin DB11, GALM, Birmingham, 2017 5 DB11 – Project Mission Next Generation Platform 2016 Coupe Aston Martin DB11, GALM, Birmingham, 2017 6 DB11 – Project Mission Next Generation Platform Aston Martin DB11, GALM, Birmingham, 2017 7 DB11 – Project Mission Brief “The world’s most timeless and elegant sports grand tourer” • The heart of Aston Martin: The fulcrum of our sports car range • Supreme elegance and sports car precision, agility and effortless touring ability • Exceptional breadth of character: GT composure allied to sports car excitement • Forceful performance and everyday usability Aston Martin DB11, GALM, Birmingham, 2017 8 21 months exterior design freeze to J1 18 months interior design freeze to J1 DB11 – Project Mission Usability & Package +149 +54 +95 1145 637 Legroom Couple +65 2805 +50 4739 Aston Martin DB11, GALM, Birmingham, 2017 9 DB11 – Project Mission Usability & Package +76l +9 260l 982 Boot volume Headroom -3 1279 +38 DB9 Passenger Seat Isofix 2060 Only 2 Rear Seat Isofix Positions Aston Martin DB11, GALM, Birmingham, 2017 10 DB11 – Project Mission Performance Performance Change from DB11 DB9 V12 Displacement: 5.2l -13% Power: 600bhp +18% CdA: <0.650 -17% 0-62mph (100kph): 3.9s -15% 0-100mph <8.0s -16% Vmax: >200mph +10% CO2g/(km * bhp): <0.5g -26% Aston Martin DB11, GALM, Birmingham, 2017 11 DB11 – Project Mission Exterior Design • Floating Arc cantrail • Large highly sculpted front hinging aluminium clamshell • Iconic and authentic Aston Martin Grille • LED headlamps Aston Martin DB11, GALM, Birmingham, 2017 12 DB11 – Project Mission Interior Design • All new electrical architecture • Electrically operated centre console • First time application of knee airbag for Aston Martin Aston Martin DB11, GALM, Birmingham, 2017 13 DB11 – Project Mission Architecture Manufacturing Summary Aston Martin DB11, GALM, Birmingham, 2017 14 Architecture Architectural Goals Highly Efficient Structure Generous GT State of the Art Packaging Aerodynamics Robust Safety Beautiful Styling Aston Martin DB11, GALM, Birmingham, 2017 15 Architecture Architectural Goals Highly Efficient Structure Generous GT State of the Art Packaging Aerodynamics Robust Safety Beautiful Styling Aston Martin DB11, GALM, Birmingham, 2017 16 Architecture Material Mix – Underframe DB9 • Aluminium Extrusion intensive whilst also utilising gravity die Castings and both simple and superplastically formed 5XXX Series Sheet 0% 0% Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles Aston Martin DB11, GALM, Birmingham, 2017 17 Architecture Material Mix – Underframe DB11 Platform • Over twice the amount of aluminium sheet metal used compared to DB9 • 6XXX series sheet for increased strength over 5XXX series • Integration of a one piece structural bodyside 18% 6% 41% 35% Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles DB11 Underframe Aston Martin DB11, GALM, Birmingham, 2017 18 Architecture Material Mix – Underframe • Aluminium Sheet metal used in areas for package efficiency, organic development through CAE, robust body sealing and dimensional accuracy 18% 6% 41% 35% Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles Aston Martin DB11, GALM, Birmingham, 2017 19 Architecture Material Mix – Underframe • Aluminium gravity die castings for integration and complex nodal joints 18% 6% 41% 35% Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles Aston Martin DB11, GALM, Birmingham, 2017 20 Architecture Material Mix – Underframe • Aluminium extrusion profiles for crash load paths and reinforcements 18% 6% 41% 35% Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles Aston Martin DB11, GALM, Birmingham, 2017 21 Architecture Material Mix – Body + Closures 11% 42% 38% 4% 5% DB11 Body & Closures Material Mix (ExcludingAluminium Die Underframe) Castings Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Mild Steel Sheet Sheet Moulding Compound (SMC) Aston Martin DB11, GALM, Birmingham, 2017 22 Architecture Material Mix – Body + Closures Closures Skins Front End Module Bridging Structure Aston Martin DB11, GALM, Birmingham, 2017 23 Architecture Mass Reduction Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg +14kg 40kg -15kg -8kg 268kg 247kg DB9 DB9 BIW DB11 Aston Martin DB11, GALM, Birmingham, 2017 24 Architecture Mass Reduction Structural Style + Requirements Package +5kg 19kg +14kg 268kg DB9 DB9 BIW Aston Martin DB11, GALM, Birmingham, 2017 25 Architecture Mass Reduction Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg 40kg -15kg -8kg 268kg 247kg DB9 DB11DB9 BIW BIW DB11 Aston Martin DB11, GALM, Birmingham, 2017 26 Architecture Mass Reduction Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg 40kg -15kg -8kg 268kg 247kg DB9 DB11 BIW DB11 Aston Martin DB11, GALM, Birmingham, 2017 27 Architecture Mass Reduction – Optimisation Topology Optimisation Design Space Creation Aston Martin DB11, GALM, Birmingham, 2017 28 Architecture Mass Reduction – Optimisation Topology Optimisation • Topological optimisation to minimize mass using derived stiffness targets for multiple loadcases Aston Martin DB11, GALM, Birmingham, 2017 29 Architecture Mass Reduction – Optimisation Topology Optimisation Where material CAE CAD Initial concept to CAE CAD Final Production is wanted deliver load Form paths Aston Martin DB11, GALM, Birmingham, 2017 30 Architecture Mass Reduction – Optimisation Casting Shape Optimisation Design Space for Casting Shape CA CAE start of shape D optimisation from optimisation CAE into CAD Aston Martin DB11, GALM, Birmingham, 2017 31 Architecture Mass Reduction – Optimisation Casting Shape Optimisation Casting Final manufactured Starting model for CA manufacturing CA form w/ optimised CAE CAE CAE D simulation D mechanical properties development sympathetic to stress and wall thickness map for wall thickness optimisation Aston Martin DB11, GALM, Birmingham, 2017 32 Architecture Mass Reduction – Optimisation Gauge Optimisation • Completed throughout design development to inform design and understand redundant material • First applied using global statics and dynamics… • …then iteratively balanced with energy management requirements • Applied with component manufacturing feasibility constraints and for commercial benefit of sheet availability Aston Martin DB11, GALM, Birmingham, 2017 33 Architecture Mass Reduction – Optimisation Stamping Simulation • Finished part gauge prediction using forming simulation • Finished Part strength and elongation mapping ! further gauge optimisation Thinnin Effective Plastic g Strain Map Aston Martin DB11, GALM, Birmingham, 2017 34 Architecture Mass Reduction Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg 40kg -15kg -8kg 268kg 247kg DB9 DB11 BIW DB11 Aston Martin DB11, GALM, Birmingham, 2017 35 Architecture Mass Reduction – Joint Design / Integration Functional Integration – A Pillar Castings • Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement Aston Martin DB11, GALM, Birmingham, 2017 36 Architecture Mass Reduction – Joint Design / Integration Functional Integration – A Pillar Castings • Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement • IP Cross Car Beam Mountings 6 Major Vehicle Systems Mounted to 1 Node Aston Martin DB11, GALM, Birmingham, 2017 37 Architecture Mass Reduction – Joint Design / Integration Functional Integration – A Pillar Castings • Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement • IP Cross Car Beam Mountings 6 Major Vehicle Systems Mounted to 1 Node • Node Also Forms Major Part of the Loadpaths for: - Roof Crush - Front Impact (e.g. 64ODB) - Side Impact (e.g. Fed side barrier) - Torsional & Bending Stiffness Aston Martin DB11, GALM, Birmingham, 2017 38 Architecture Mass Reduction – Joint Design / Integration Functional Integration – Front Damper Mounting • Sand Cored hollow die casting used to reduce part count and optimise package space to larger engine and for structural efficiency Hollow 9 Parts Sand core into 1 DB9 DB11 Aston Martin DB11, GALM, Birmingham, 2017 39 Architecture Mass Reduction Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg 40kg -15kg -8kg 268kg 247kg DB9 DB11 BIW DB11 Aston Martin DB11, GALM, Birmingham, 2017 40 Architecture Mass Reduction – Materials • VH Platform used 5XXX for sheet metal 350 • 5XXX series has excellent formability but low strength in comparison to those 300 available in heat treated 6XXX series 250 • Heat Treatment required to achieve best
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