EDAG INSIGHTS 1/15 - EDAG Light Cocoon 1

EDAG INSIGHTS 1/15 EDAG Light Cocoon

PROGRESSIVE AUTOMOBILE DESIGN AND BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES AND ADDITIVE MANUFACTURING PROCESSES EDAG INSIGHTS 1/15 - EDAG Light Cocoon 2

EDAG Light Cocoon

PROGRESSIVE AUTOMOBILE DESIGN AND BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES AND ADDITIVE MANUFACTURING PROCESSES

Inspired by nature. Additively manufactured. And the ultimate in lightweight design. The ”EDAG Light Cocoon“ is a visionary approach towards a compact, dynamic sports car, with a fully bionically optimised, additively manufactured vehicle structure combined with a weatherproof textile outer skin. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 3

EDAG INSIGHTS Contents

4 The 3D print revolution has begun

5 Technology roadmap of additive manufacturing

7 EDAG Genesis was only the first stept

9 EDAG Light Cocoon: The statement for future lightweight construction

13 Social relevance and sustainibility

14 The concept in details: Drive concept and package Fugenlos beweglich: The Light Cocoon‘s spoiler Personalisation via accounts

20 Conclusion

21 Editorial EDAG INSIGHTS 1/15 - EDAG Light Cocoon 4

THE 3D PRINT REVOLUTION HAS BEGUN.

Everyone is talking about „3D printing“. After consumer printers have flooded the market, industrial applications will follow. Generative manufacturing processes or additive manufacturing will leave the prototype status behind and add a new dimension to the classical manufacturing methods. Additive Manufacturing has long been in use in the automotive and aerospace industries and in medical technology. Above all, small parts and Prototypes can be produced quickly, and without the use of tools.

Despite the large number of conceivable position to be able to adopt and copy nature‘s processes on the market, the general principle is construction principles. Developed functionally the same: the material is built up layer by layer, and evolutionarily into optimised structures from without the use of tools, and only a 3D data which man can learn. And the entire process is model of the product must be available as input tool-free, resource-saving and economical. data. This method opens up enormous freedoms Processes such as the thermoplastic-based FDM in development and design which were not pre- process offer the chance of integrating fibre viously possible, due to restrictions in production elements, to represent structural parts. As a imposed by the classical primary forming, re- result, completely new concepts for ultimate shaping and machining manufacturing processes. lightweight design in automobile development Additive manufacturing processes put us in a are already emerging. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 5

TECHNOLOGY ROADMAP OF ADDITIVE MANUFACTURING

Particularly promising additive manufacturing processes have been identified and their technological effects examined as part of an intensive technology analysis carried out by EDAG experts and leading authorities in the field of additive manufacturing. During this think tank, it very quickly became clear that additive manufacturing processes offer considerably more potential than current restrictions in the field of rapid prototyping.

SLM – Selective Laser Melting FDM – Fuse Disposition Modeling

The principle of this process is similar to This process works on a principle similar to electron beam melting, in which finely that of a hot-melt glue gun: using a nozzle powdered metallic materials are selectively that moves three-dimensionally in an open melted by applying a laser beam in an inert space, melted thermoplastic polymers are gas atmosphere. The mechanical properties sprayed on layer by layer, and built up to correspond by and large to those of the basic produce a workpiece. The introduction of materials. Particle sizes are selected subject to reinforcing fibres, e.g. in the form of attached layer thickness and surface quality. continuous filaments, produces material The installation space for the parts that can properties suitable for structurally relevant be produced is limited. components. The process is still undergoing development. Further advantages of the process are the component dimensions that can be produced (range of the robot arm / additional mobile workpiece) and the possibility of being able to use bio-polymeric materials instead of petroleum-based or biologically degradable polymers. This would supply additional potential for sustainable production.

The following diagram shows an assessment of the processes in the form of a technology roadmap up to 2045. Different technological leaps (so-called booster potential) were recorded and analysed, to assess the extent to which they might contribute to the generation of larger vehicle parts. Overall, metal-based SLM and thermoplastic-based FDM looked to be particularly interesting and promising.

For details of the technology roadmap and the other processes, see edition 1/14 of EDAG Insights EDAG INSIGHTS 1/15 - EDAG Light Cocoon 6

THE EDAG ROADMAP: THE EVOLUTION OF ADDITIVE MANUFACTURING IN THE COURSE OF THE NEXT DECADES

2015 2025 2035 2045 Roadmap Additive Manufacturing

FDM SLA Fuse Deposition Modeling Stereo lithography Booster potential FDM Principle: melted thermoplastic Prinziple: selective polymerisation Booster potential FDM polymers are sprayed on and built up of fluids by laser (epoxy resins). Component Size Aligned endless fibres with high Reactive chemistry layer by layer, using a nozzle that band width A classic rapid prototyping process moves three-dimensionally in an ECOLOGICAL PERFORMANCE Plasticised material feed since the 1990s. open space. Robotics As a rule. material properties are Structural relevance The inclusion of reinforcing fibres geared to model building materials. is still currently being researched Material Range (3D fibre printer). Process Speed

Tolerance Complexity Booster potential SLM Production Costs Customised alloys SLM SLs Precision Multi-beam/scanner Selective Laser Melting Selective Laser Sintering Batch Size Weight – moulding flask Principle: electron beam melting: Principle: powdered thermoplastic Powdered metallic materials are materials are laser sintered layer by layer Booster potential SLM locally laser remelted under inert gas. in an inert gas atmosphere. Booster potential 3DP Integration of semi-finished products Portal instead of a chamber By and large, mechanical properties Mechanical properties are below those Subsequent treatment processes conform with the basic materials. of injection moulding. Optimisation of system of bonding Particle sizes are selected subject to Booster potential SLM agents for solid materials layer thickness and surface quality. In situ bonding agents Alloy developments Portal instead of printer Scale-up

Booster potential FDM Biopolymers 3DP Booster potential FDM Optimisation of fibre matrix 3D Printing High performance thermoplastics Multi-jet Booster potential 3DP

Principle: solid materials are bound together Catalytic subsequent treatment layer by layer, using suitable bonding agents.

Subsequent treatment is carried out to Booster potential SLS define the properties of the workpiece. Booster potential SLS Fibre reinforcement Simultaneous printing of plastics in Optimisation of matrix materials various degrees of hardness and colours.

Booster potential SLS Multi-beam/scanner Booster potential SLA Scale-up Integration of fibres in 2D Booster potential 3DP Consumer hype EDAG INSIGHTS 1/15 - EDAG Light Cocoon 7

”EDAG GENESIS“ WAS ONLY THE FIRST STEP

With „EDAG Genesis“, our exhibit at the 2014 a sandwich component, with fine, inlying bone Geneva Show, we provided a visionary outlook structures that give the shell its strength and for what might well be the next industrial revolu- stability. This concept is reflected in the exhibit. tion in automotive development and production. The „EDAG GENESIS“ can be seen as a symbol The skeleton can be seen as a metaphor; in this of the new freedoms and challenges in design, case, it does not form part of a musculoskeletal development and production that additive ma- system, but instead provides extra passenger nufacturing processes will open up to designers safety. The framework calls to mind a naturally and engineers. The structure is based on the developed skeletal frame, the form and structure bionic patterns of a turtle, which has a shell that of which should make one thing perfectly clear: provides protection and cushioning and is part these organic structures cannot be produced of the animal‘s skeleton. The shell is similar to using conventional tools! EDAG INSIGHTS 1/15 - EDAG Light Cocoon 8

Although the turtle had millions of years to production situation, which was unconceivable develop to suit its needs and, for instance, perfect in the past. Additive manufacturing enables its „passenger safety system“, man is still theo- parts to be designed so that they are load- retically at the very beginning of a possible para- specific, multi-functional and bionic, while digm shift. The traditional rules of design, with ensuring ideal (or „topologically optimised“) wall restrictions caused by production, will play only thickness and outstanding material properties. a very minor role in additive manufacturing, and Working directly from the data models, tool-free, the tried and tested construction methods of highly flexible production is possible. nature can also be applied in a genuine series

In 2014, the world‘s trade and economic press picked up on the EDAG Genesis and made it a subject of discussion. An intensive dialogue also sprang up between vehicle manufacturers, suppliers, manufacturers of semi-finished products, research institutes, material suppliers, additive manufacturing equipment manufacturers and the EDAG experts. The sector was made aware of these new and revolutionary concepts. Work is currently being carried out on practical uses for the impulses referred to. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 9

EDAG Light Cocoon: THE STATEMENT FOR FUTURE LIGHTWEIGHT CONSTRUCTION EDAG INSIGHTS 1/15 - EDAG Light Cocoon 10

EDAG Light Cocoon: THE STATEMENT FOR FUTURE LIGHTWEIGHT CONSTRUCTION

Following the „EDAG Genesis“ vehicle sculpture, we have expanded the vision of a bionically inspired body structure. In doing so, we are pursuing sustainable approaches – as demonstrated by nature: lightweight, efficient, and without any waste.

We are working on the assumption that it will basic requirements of the automotive industry. take some 10 years for the vehicle to be realised Specially for this purpose, existing calculating in about 2025. The core idea of the „EDAG Light methods needed to be adjusted or new ones Cocoon“ concept is not to regard the body as developed in advance, to reduce the structure on a closed surface. Instead, an approach was load paths (the paths that loads follow as they adopted in which material was only actually pass through a component). The result: used in areas where it was necessary for the „EDAG Light Cocoon“ presents the same function, safety and stiffness. This means that kind of stable, branch-like load bearing structure the sheet metal surfaces that typically make up that can be seen in nature. Despite the fact that the outer skin of a vehicle were broken up. less material has been used, all requirements The ideal geometrical structure was validated by imposed on structurally relevant components our CAE team, to ensure compliance with the are met. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 11

Bonnet A, Source EDAG Bonnet B, Source EDAG

Simulation on the basis of a series bonnet simple geometry for the structure of the To first of all quantify and then verify the light- bonnet, see diagram in upper left-hand corner. weight potential of a bionically designed This structure is not able to withstand the structure, this approach was previously used, for dynamic load cases, e.g. to meet head impact example, in the design of the bonnet of a specifications, as the hole pattern is too open. production vehicle, and then calculated. The The diagram in the upper right-hand corner point of the calculations was to confirm require- shows the geometry that will meet the ments, e.g. with regard to torsional and flexural requirements of the head impact test. stiffness, and also to pedestrian protection. The calculation results confirmed two things: The results of the topological CAE calculation that the basic stability requirements were met, simulation are promising: a vehicle‘s bonnet is an and that a weight saving of approx. 25 % was extremely complex component which is subject achieved with this bonnet (achieved in an to both static and dynamic load cases. In order exemplary fashion by using aluminium profiles to withstand the static loads, there is a very of different thicknesses).

EDAG INSIGHTS 1/15 - EDAG Light Cocoon 12

Fabric outer skin To protect the vehicle from the effects of the weather in spite of its open structure, but still meet aerodynamic principles, an additional fabric covering was designed for the EDAG Light Cocoon.

The leaf of a plant served as the blueprint for the innovative design of the body shell. Just like the structure of a leaf, which has a lightweight outer skin stretched over it, a lightweight protective skin covers the EDAG Light Cocoon – though in this case, it is made of a textile fabric.

In Jack Wolfskin, outdoor specialists, the ideal project partner was found to supply a tried and tested stretch fabric that is also extremely weatherproof, to serve as the new outer body skin. TEXAPORE SOFTSHELL O2+ is a triple- layered polyester jersey fabric, which is extremely lightweight, durable and watertight. The material‘s excellent elasticity is what qualifies it for the bionic structure of the EDAG Light Cocoon, as provides a perfect fit. Weighing no more than 19 g/m², the Jack Wolfskin materials support maximum lightweight design requirements with minimum weight.

The conscious separation of the structure and outer skin surface makes it possible for the first time ever to consider the use of textile materials for the exterior, as these do not have any structural tasks to fulfil. Thanks to an LED back light concept, the interaction between light, structure and fabric created attractive – and above all – innovative vehicle aesthetics. Apart from the ornamental effect, this also makes a tactile experience possible EDAG INSIGHTS 1/15 - EDAG Light Cocoon 13

SOCIAL RELEVANCE AND SUSTAINABILITY

Should it prove possible to implement processes and technologies of this type in series production in the foreseeable future, this will have far-reaching effects on our society, and may help to preserve our ecosystem.

Production will first of all become waste-free and that our present computer-based software for resource-saving, and, with the thermoplastic the styling, development, design, calculation and processes, we will also later be able to draw on production phases is not in line with the new nature-based materials, the biopolymers. We will processes. then be able to produce products on-demand – without major warehousing or transport costs, However, this will give rise to completely including the effects they have on the environ- different questions. If the design data, which will ment – since these new factories will be decen- then be restricted to the surface data of the tralised, which will mean fewer resources, less products and their spare parts, is made available complexity and lower investment. The same on the Internet – simply scanning the surface of will then also apply to the procurement and a product will suffice – then the question of in- production of spare parts, and the provision and tellectual property rights will arise. We are alrea- servicing of tools beyond the production period. dy experiencing similar problems in other fields, In this case, the networking of development and e.g. the music, film and photographic industries. production in the sense of the „smart factory“ would be not so much a means to an end as It is therefore evident that, although there will absolutely essential. be a great many chances for new business models (e.g. online 3D print shops, integrated These new production processes will also have 3D scanner software in smartphones), there will an effect on our development processes, as also be many risks for any companies that fail all the familiar restrictions previously linked to to consider the general context. production-oriented development will become obsolete. Suddenly, it is possible to produce Wer are on the threshold of a possible paradigm anything! The new processes enable us to +6 shift for which nobody is currenntly prepared, reproduce nature, and bring us one step closer so it remains to be seen how we organize and to adapting bionic thought patterns. It will, orientate ourselves in the relevant areas, and however, be necessary to introduce our future which industry will play the leading role in designers and engineers to these ideas and train establishing additive manufacturing processes in them accordingly, and we will come to realise series production. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 14

The concept in Details EDAG INSIGHTS 1/15 - EDAG Light Cocoon 15

Details

Class: Sports car, two-Seater Lithium ion battery: 59 kWh Target weight: 1,250 kg Consumption over 100 km: optimal 13 – max. 25 kWh Range: approx. 350 km Motor: Hybrid synchronous motor 0 – 100 km/h: approx. 6 sec. 185 kW Vmax: 150 km/h Torque: 380 Nm

According to the basic idea of constructing the Motors of this type are already available, and the EDAG Light Cocoon as a two-seater sports car for necessary amount of installation space has been the year 2025, an overall length of almost 4.2 m taken into account in the overall vehicle package. and a wheelbase of 2.5 m were defined. This puts The energy is fed to the motor by a T-shaped the car in the same vehicle class as an Audi TT or battery pack. The layout selected guarantees a BMW Z4. Due to the car‘s bionic, topological that the centre of gravity is low and positioned optimisation, its overall weight is 1,250 kg. Due towards the rear, and also meets the styling to the central electric motor, we have achieved an department‘s requirements for a very sporty acceleration rate of 0 to 100 km/h in about vehicle line. In addition, this layout also means 6 seconds. that a large-volume hydrogen tank can be used without any problem. Drive concept and package To accommodate the idea of sustainability in the drive concept, too, the EDAG Light Cocoon has been designed as a fully electric vehicle. At its heart, there is to be a 185 kW central electric motor which will drive the rear axle, and has a torque of 380 Nm. More than enough power for a fast overtaking manoeuvre in a car with an Control electronics overall weight of 1250 kg.

Battery pack EDAG INSIGHTS 1/15 - EDAG Light Cocoon 16

When selecting a suitable energy storage system, luxury features such as air conditioning or an the first thing to do was to anticipate future infotainment system. A value that is geared to technological developments. It is reasonable to factory specifications for current electric vehicles, assume, and this is in line with the NPE roadmap and already realises the savings potential, (National Platform for Electric mobility), that there particularly with the ancillary equipment. will not be any technological disruption or technology changes to battery storage (to Li-air/Li-S For a desired range of 350 km, we assume that batteries) until after 2025. Until such time, the an energy storage system capable of producing evolutionary development of the safety, energy an energy quantity of 59 kWh will be required. density and, above all else, price of existing Li-ion Since we anticipate that a reliable quick charging technology is expected. Current advances give rise infrastructure will have been established by 2025, to expectations that capacity will soon increase a range of 350 km will be sufficient to allow the by around 50 %, while volume and weight will vehicle to be used anywhere. The vehicle will remain unchanged. Our estimates for the Light move intelligently within the power supply Cocoon are based on the assumption that capa- system. Short breaks that will have to be taken city at system level will increase by a conservative to top up the car‘s energy supplies will not in any 40 % with conventional technology, which seems way impair its use, despite the limited amount of very likely to happen by 2025. energy available.

If we look at the multi-cell batteries in standard In special application scenarios (e.g. if it is being use today, they already produce volumes of used exclusively for long distances or in countries energy between 23 and 43 kWh and ranges from which do not have a charging infrastructure), a 180 to 335 km. As we see it, the 40 % evolutio- range extender might still be advisable. nary development that we are assuming will be sufficient to ensure reliable ranges beyond the 350 km mark from 2025 onwards.

We are assuming that the EDAG Light Cocoon will have a consumption value between 12.9 and 25 kWh/100 km, depending on

Control electronics

Hydrogen Storage

Battery pack

Range Extender EDAG INSIGHTS 1/15 - EDAG Light Cocoon 17

From today‘s point of view, conventional internal short supply in an electric vehicle. It must also be combustion engines are generally ideal for use treated as a scarce commodity by the auxiliary as range extenders, to vary the battery size and equipment. Good energy management will be therefore the cost. Unfortunately, this measure essential for future vehicles. Important factors does away with the advantages of a fully elec- such as range, performance and comfort are tric vehicle (CO2 neutrality, low noise emissions, decided here, and so, along with the develop- etc.). For this reason, we decided to install a ment of energy storage systems, make a decisive revolutionary, zero-emission range extender contribution to the breakthrough of renewable which is based on fuel cell technology in the energies. Here, too, the EDAG Light Cocoon EDAG Light Cocoon. Fuel cell systems are profited from EDAG‘s engineering competence currently undergoing rapid technological de- in the field of power electronics and distribution, velopment, and offer great potential for the energy management and battery systems. efficient generation of constant energy. In the EDAG Light Cocoon package, the position defined for the optional hydrogen tank is the area in front of the rear axle – the safest place with a view to rear and side collisions. The battery volume is reduced to accommodate the hydrogen tank.

In the first calculations carried out using this approach, the EDAG experts achieved a range of more than 500 km. Energy management proved to be a further challenge. Energy is in particularly EDAG INSIGHTS 1/15 - EDAG Light Cocoon 18

Fabric stretched Approx. 70 mm Fabric

Seamless mobility: To bring about this optical highlight, a number The Light Cocoon‘s spoiler of technical challenges first had to be solved. Apart from offering a high degree of lightweight As the requirements were for the vehicle‘s potential, the use of a flexible textile fabric also spoiler to remain inflexible in its movement, for opens up other chances. Moving components the cover plate to be bent and also the length can be covered just as easily as the rest of the of the spoiler‘s edge to be adjusted, a material vehicle. This idea was first used on the Light capable of meeting these high standards had to Cocoon‘s mobile spoiler. Conventional spoilers be found. rely on mobile components. A concertina wall is generally used to optically integrate this wing What the EDAG experts found was a special into the vehicle. Furthermore, in its retracted PU material able to withstand the tensile stress state, it creates a very pronounced visual effect. and deformation. With the help of two infinitely variable servo motors, the spoiler can be electro- Due to the hi-tech fabric used on the Light mechanically adjusted to suit the vehicle‘s speed. Cocoon, when the spoiler is extended, this is Fully extended, the servo is an impressive 7 cm tantamount to a geometrical adjustment of high. The airflow around the rear end of the car the vehicle body. The fabric performs every is ideal, providing the necessary down force. movement required of it. There are no joins to detract from the vehicle‘s appearance, no extendable components to generate down force due to the airflow. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 19

Personalisation via accounts can, for instance make configurations and Car owners want to personalise their vehicles. settings offline, and then activate them in the That does, however, mean more than just car. His data is always available without being ordering a few extras from the manufacturer‘s directly dependent on the car. Also, the cloud- list of accessories. We are already familiar with based mapping of some of the functions can the practice of creating our own ideal mobile transfer computing power away from the car. phone profiles by means of optional settings and apps, and customers want to be able to make From the manufacturer‘s point of view, there are use of a similar range of functions in their cars also additional opportunities for ensuring brand in the future. Possible vehicle settings might be loyalty. Once acquired, functions can be used in seat adjustments, media play lists, display compatible vehicles of the same brand. Com- configurations, themes, but also a preferred pared with the high cost involved if the brand chasis setting. With the EDAG Light Cocoon, is changed, the low cost of changing within the a further dimension is added. The innovative same vehicle brand could make this lock-in exterior lighting technology enables the custo- effect very attractive to customers. mer to present his vehicle in any lighting set-up imaginable. On account of the far greater transparency in the pricing of features, however, the manufac- With the EDAG vehicle, the concept of persona- turers will in the future have to make the added lisation is taken one step further: features are no value of these functions perfectly clear. It will longer defined in the vehicle; instead, they are then be possible for the rising cost of software linked to a personal account. This makes the development, for instance, to be offered and account-related activation of selected vehicle financed separately. And the manufacturers can functions possible. This idea provides the draw on EDAG‘s know-how when it comes to customer with numerous advantages: the driver this task.

Possible personalisation in the interior of the EDAG Light Cocoon. The use of fabric as a very flexible projection surface in the interior offers a high degree of freedom in the adjustment of the controls via a personal account. EDAG INSIGHTS 1/15 - EDAG Light Cocoon 20

CONCLUSION

We will continue to keep a close watch on the evolution of additive manufacturing. The target: to develop practicable and valid applications for use in component development and production.

There are already plans to present a number of bile production. As an engineering company, selected, structurally relevant components using we see it as our task to make sure that we are different materials and additive manufacturing today already working on technologies of the methods at the IAA 2015 in Frankfurt. future and completely new approaches to In addition to this, we will also continue to press vehicle development. When it comes down to it, ahead with subjects related to connecting the working on concept car projects like the „EDAG vehicle up to the Energy Internet, and to the Light Cocoon“‘ enables us to build up additional personalised car account. competencies within our company, while at the same time also encouraging people to think With the futuristic concept of our „EDAG Light outside the box and tread new paths in order to Cocoon“, we want to make a conscious con- achieve the best possible technical solutions. tribution to stimulating the discussion about the People like us, who develop the cars of tomorrow, future of lightweight construction and automo- must always keep their focus on the day after tomorrow. EDAG INSIGHTS

WOULD YOU LIKE TO KNOW MORE ABOUT bionic Design and the EDAG Light Cocoon? THEN ASK US.

Johannes Barckmann, EDAG, Head of Design Studio

Contact: Tel.: +49 661 6000-610 [email protected]

Heiko Herchet, EDAG, Project manager, Electric Mobility

Contact: Tel.: +49 661 6000-9098 [email protected]

Authors of this Edition Johannes Barckmann, Heiko Herchet, Michael Pollner