COMPOSITES LEADERSHIP FORUM
Automotive Composites Group: Henry Sarel-Cooke Chair GKN Wheels and Structures Sept 13th 2018
Contact Details: Tel:07825864091 Email: henry.sarel-cooke@gkn.com
Composites Leadership Forum 1 Latest News
• 2018 has seen further increases in UK Automotive Composites demand. • Predictions for 2019, demand will exceed 40,000 tonnes. • From 2020 this will incrementally increase by a further 50,000 tonnes. • 20 further UK fibre lines to open 2019 with additional capacity added in 2020. • OEMs and Tier 1s to invest a further £500m in composite components and assembly processes.
No, It’s all a dream. It’s not happening!!!!
Composites Leadership Forum 2 Challenges
• Cost: – Raw material – Yield – Takt time –Waste • Electric Drive Trains – Prioritised by OEMs • Recyclability •Risk – NDT – Joining • Supply chain – Not joined up – Lacks critical mass.
Composites Leadership Forum 3 Automotive Composite Group
Established by the Automotive Council’s Manufacturing Members include: Group and the CLF. The Group is chaired by Henry – McLaren Sarel-Cooke of GKN. –JLR Aim: “to facilitate development of UK technology – Nissan capability and supply chain capacity to deliver high – Aston Martin productivity manufacturing of globally competitive, higher – Williams volume composite structures and components”. –GKN The ACG has set targets, mapped out the supply chain development required and is now seeking to fill gaps that – Solvay could restrict future development. – Gordon Murray Design It is working with Government and funding bodies to – Nippon Electric Glass identify funding mechanisms to facilitate this. – Nottingham University – National Composites Centre – Dept for International Trade – Innovate UK –HVMC – APC
Composites Leadership Forum 4 CLF ACG Areas of Focus
• Delivery of the composites part of the Auto Council Light weighting roadmap: – ISCF Challenge fund bid ‘Materials for Future Mobility’ contains: – Manufacturing Development - Composites Large Scale Project: Preforming development led by HVMC, consortium including Bentley, Ford, JLR, McLaren, Nissan, GKN, Gestamp. – Materials Development – National Composites Materials Centre: Focused on materials supply chain development. • If ISCF not successful. ISCF4? Lightweighting? • Engagement with Auto OEMs and Tier 1s. • Workshops to develop Innovate UK and APC collaborative proposals. • Supply chain mapping and analysis. Possible Solutions
• Material choices – Thermoset. SMC. • Net shape capability • Complex Geometry • Inserts • “Clever components” • Right material – Right place. – Thermoplastics • Material cost •Takttime • Recyclability – 3 D Net Shape • Standard RTM process • Snap cure resins. • Quick cycle time. • Use of recycled material • Government Intervention – Mitigate risk.
Composites Leadership Forum 6 Automotive priorities 2018+
2017 2020 2025 ACG FOCUS HOW? Increase Process Yield Manufacturing Processes Work with Supply Chain and HVMC to Reduce cycle time & no. of process improve key processes and disseminate steps (CFRP, GFRP) knowledge
ACG FOCUS Thermoplastic Composites HOW? Accelerated development support for Prioritise development with CLF Technology early adoption (GFRTP, CFRTP) Group and HVMC
ACG FOCUS HOW? Create pull for local supply of cost Support CR&D projects, Sector Deal (Materials effective intermediates Cost Effective Intermediates development), HVMC CLSP and dissemination
ACG FOCUS HOW? Define needs for composite and multi‐ Interface with and support wider programmes material joining techniques and Joining Technologies (HVMC Joining Forum), CR&D and shared support shared practice practice
HOW? ACG FOCUS Interface with other groups, (APC Digital Support accelerated awareness, Improved Design & CAE Tools Spoke, HVMC, Supply Chain). Support development, validation and rollout workshops and validation
ACG FOCUS HOW? Ensuring cost effective and rapid Cost Effective Tooling Interface with other groups, (Aero, HVMC, development tooling is available for Supply Chain). Support workshops and mass production validation Next Generation Composite Manufacturing Paul Gallen HVM Catapult (Composites Large Scale Project – CLSP) 22nd August 2018 Contact : [email protected] What we do
Drive growth of Take the risk out manufacturing of innovation Help companies of Give business access to: all sizes incubate — World class open sourced equipment and develop new technologies to — The UK’s best relevant research knowledge commercial reality — At elbow support from engineers, scientists, technicians — An environment of collaboration and open innovation • Cross sector • Cross technology • Whole supply chain • Even among direct competitors HVM Catapult centres
AFRC
CPI
Nuclear AMRC AMRC MTC WMG
NCC 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 chains, including tooling and design
• 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 identified as a potential funding source to deliver objectives Implication of the Revolution in Future Mobility Trends
Connected Electric
Weight increases
Autonomous Shared Drivers for Light weighting in Transport
Cleaner – Range emissions targets
Light weighting Industrial Performance opportunity demands UK Automotive Lightweighting Opportunity
Hybrid: +10% vs today
New content New features (self‐steering, ADAS) Legislation (small overlap crash) ~ +5% increase per decade Weight Challenge Vehicle 10‐15% / decade CHALLENGE Mass AVERAGE weight reduction of existing systems must be: 10‐15% per decade
CHALLENGE TYPICAL on‐cost not to exceed £2.50 to £5 per kg of weight saved
CHALLENGE EXISTING vehicle end of life recycling target requires > 85% recyclability 2016 2020 2025 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 2025 AVERAGE weight reduction of existing systems of 15% UK automotive Global automotive composite prediction ACG TARGET 2025 composite prediction (DIT) TYPICAL on‐cost not to exceed £5 per (Persistence Market Upper Research) kg of weight saved
ACG TARGET 2025 POTENTIAL MARKET IMPACT TYPICAL takt time 60s £3.5 bn p.a. by 2030 Lower UK supply chain globally ACG TARGET 2025 competitive EXISTING vehicle end of life recycling In place for window of opportunity > 85% recyclability Key areas of Focus & Impact
• Market alignment: • Common set of challenges across 5 OEMs • ~40 supply chain aligned with appetite to deliver these challenges • Agreement on demonstration of capabilities • First cluster opportunities / supply chain improvement (Auto composites & Technical Textiles) • Alignment of Trade body working groups (CLF, CUK, Catapult, ACWG) EOI Summary: Next Generation Composites Manufacturing OUTCOMES Long‐term high value capture, competitive and innovative UK manufacturing, adoption of & BENEFITS productive technologies Scaled OEM & T1 specific projects Cluster support Industrialisation £20M APC
Demonstration of Capabilities (Prototypes, tooling, processes, supply chain, digital manufacturing and high value design) £10M ISCF Challenge Technology matching Design & CAE tools BRUNEL CHALLENGE Cost & Process Highly competitive advanced & “MADE SMARTER” modelling. value chains identified £20M ISCF Automation, Digital Funding Representative Manuf. and rate Aspirations and Gaps attributes derived: increase support understood OEM relevant generic Volume demonstrator • Delive Cost “Pool” of competitive Existing UK composites components identified Rate Quality manufacturing supply‐chain Weight technologies and capabilities and Properties knowledge capacity understood Early OEM Component Technology UK Supply Chain Engagement Development Development Development Programme Outcomes
• Secure ISCF funding support or equivalent for programme over 3 years (2019‐22) with 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.
Our request to you • Get in touch if you are interested and are not Contact: [email protected] already engaged ACG: Potential UK Opportunity Post 2020
UK Car EU Car production sales From 2020 onwards (SMMT estimate) (EU28 actual) 2020 2011 Aluminium & Thermoset Supercar (S) Composites UK produces high 54% 5% Luxury (F) (700k) proportion of (1.13M) heavier/ Exec (E) Aluminium & Aluminium, expensive cars SUV (J) Steel Steel & TP 26% 26% Multi- Composite (546k) (3.3M) “lightweighting purpose (M) opportunity” Large (D) Steel & Thermoplastic Medium (C) 20% 69% Composites (420k) (10M) Small (B) Mini (A)
2.1M 14M Passenger Car Market Segments
Composites Leadership Forum 19 APC UK – “The Roadmap Report” June 2018
Composites Leadership Forum 20