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BMW I3 PLANT TOUR FACILITY the LEIPZIG Show Review Nesting Update Turbine Concept Turbine Cutting, Kitting & 2014 JEC Europe Umaine Floats New 3 NO

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BMW I3 PLANT TOUR FACILITY the LEIPZIG Show Review Nesting Update Turbine Concept Turbine Cutting, Kitting & 2014 JEC Europe Umaine Floats New 3 NO JUNE 2014 | VOL. 20 | NO. 3 compositesworld.com THE LEIPZIG FACILITY BMW i3 PLANT TOUR Cutting, Kitting & Nesting Update UMaine Floats New Turbine Concept 2014 JEC Europe Show Review 0411 A&P.indd 1 3/17/11 8:12 AM Table of Contents June 2014 | Vol. 20 | No. 3 COMPOSITES WATCH Energy | 15 News | 17 18 24 COLUMNS Editor | 3 Where are they now? Composites: Past, Present & Future | 5 Composites: Perspectives & Provocations | 11 By the Numbers | 13 32 46 DEPARTMENTS FEATURES Applications | 38 2014 Europe Review Calendar | 39 18 The composites world met again in Paris, vibrant, stronger, New Products | 40 and more forward-looking than ever before. Marketplace | 44 Ad Index | 45 Plant Tour | The Epicenter Showcase | 45 24 of i3 Production A glimpse into the inner workings of an automaker at the forefront of serial-production autocomposites. COVER PHOTO By Jeff Sloan Cutting & Kitting Update | 32 Automated Cutting Accelerates Software/hardware advances and peripheral equipment make flatbed cutters essential to automated production scenarios. By Sara Black Focus on Design | GFRP Enables 46 First Grid-connected U.S. Floating The Munich, Germany-based BMW Group’s Leipzig manufacturing plant is rolling Wind Turbine out 100 of its stylish new i3 all-electric Composite tower on 1:8-scale system reduces hull size/weight commuter cars per day. The car’s carbon fiber composite passenger protection cell, and helps mitigate the overall cost of electric power generation. what BMW calls its Life Module, is molded By Sara Black and assembled in a highly automated production scheme. CT got inside for a close CT JUNE 2014 look. Read about it on p. 24. Source | BMW AG 1 ® COMPOSITE CONCEPT CAR • Bio-sourced EnviroGuard® unsaturated polyester resin • Light weight, with high cosmetic aspect- design benefit • Eco-efficient resin, enables users to consume less natural resources and reduce their environmental aspect The concept car was built through a collaboration between several companies, including CCP Composites, Hutchinson, Total RC, Atotech and Bostik. Look to CCP Composites for all your sustainable solutions. For more information, visit www.ccpcompositesus.com For industrial use and professional application only. Consult the CCP Composites US website for complete product information. www.ccpcompositesus.com 800-821-3590 0614 CCP.indd 1 4/24/14 10:57 AM Editor EDITORIAL OFFICES Publisher Richard G. Kline, Jr. / [email protected] Editor-in-Chief Jeff Sloan / [email protected] Managing Editor Mike Musselman / [email protected] Where are Technical Editor Sara Black / [email protected] Senior Editor Lilli Sherman / [email protected] Senior Editor Ginger Gardiner / [email protected] they now? Graphic Designer Susan Kraus / [email protected] Marketing Manager Kimberly A. Hoodin / [email protected] Midwestern U.S. & International Sales Office We first heard about the vehicle now known as the BMW i3 in 2010 at the JEC Associate Publisher Ryan Delahanty / [email protected] Eastern U.S. Sales Office show in Paris. There, we met for the first time Andreas Wüllner and Jörg Pohlman, District Manager Barbara Businger / [email protected] managing directors of the then new joint venture between SGL Group and BMW Mountain, Southwest & Western U.S. Sales Office District Manager Rick Brandt / [email protected] Group, called SGL Automotive Carbon Fibers (SGL ACF). Wüllner and Pohlman European Sales Office told us about a new all-electric passenger car BMW was developing, called the European Manager Eddie Kania / [email protected] Megacity Vehicle. It would feature a passenger cell made entirely of carbon fiber, Contributing Writers which would be captively sourced from SGL ACF at a new plant to be built in Dale Brosius / [email protected] Donna Dawson / [email protected] Moses Lake, Wash. The car, they said, would be a production vehicle and thus Michael LeGault / [email protected] would represent the first use of substantial amounts of carbon fiber in a car osten- Peggy Malnati / [email protected] Karen Wood / [email protected] sibly targeted toward the everyday driver. That vehicle, which became the BMW i3, is on this month’s cover, and on p. 24 you’ll find the i3 plant tour we have long looked forward to. Now, the i3 is on the 6915 Valley Avenue Cincinnati OH 45244-3029 market in Europe and in the U.S., BMW is making 100 i3s a day and the sporty P 513-527-8800 hybrid i8 — also featuring a carbon fiber passenger cell — is due out later this year. Fax 513-527-8801 gardnerweb.com So, it appears that the long-awaited elec- tric vehicle (EV) culture is here. There is, PO Box 992, It appears the electric Morrison, CO 80465 however, a certain amount of déjà vu. The P 719-242-3330 vehicle culture is here, Fax 513-527-8801 same year we met Wüllner and Pohlman, we compositesworld.com published in CT a story about other up-and- but there is a certain Richard G. Kline, CBC | President coming electric vehicles that promised to amount of déjà vu at Melissa Kline Skavlem | COO use composites for lightweighting. We wrote Richard G. Kline, Jr. | Group Publisher about Myers Motors’ two-seat Duo and one- work. Tom Beard | Senior V.P., Content seat NmG. We reported on Tesla’s Model S Steve Kline, Jr. | Director of Market Intelligence EV and the two-seat Aptera 2 Series being developed by Aptera Motors. We told Ernest C. Brubaker | Treasurer William Caldwell | Advertising Manager you about Fisker Automotive’s hybrid-electric Karma. Where are they now? Ross Jacobs | Circulation Director The Tesla Model S lives on, but all of the others saw either limited or no life in Jason Fisher | Director of Information Services production. Fisker, running out of money, entered bankruptcy in 2013 and was Kate Hand | Senior Managing Editor acquired by Wanxiang America Corp., which might or might not resume produc- Jeff Norgord | Creative Director tion of the Karma. Myers Motors is alive, but production of its EV depends on a Rhonda Weaver | Creative Department Manager Dave Necessary | Senior Marketing Manager crowd-funding campaign. Cash-strapped Aptera was forced to close its doors in Allison Kline Miller | Director of Events late 2011, was subsequently bought by Chinese automaker Jonway and reactivated as Zaptera USA, which in turn created Aptera USA. Aptera USA has promised to ALSO PUBLISHER OF produce the Aptera 2 Series, but as of mid-May, it was nowhere to be seen. • High-Performance Composites • Modern Machine Shop • IMTS Directory • NPE Official Show Directory The bottom line here is, well ... the bottom line. Developing and manufac- • Moldmaking Technology • Production Machining turing cars is expensive, and not for the shallow of pockets. The consumer market • Products Finishing • Products Finishing Directory • Plastics Technology / PT Handbook • Automotive Design & Production might be ready for smaller, nimbler, lighter, urban-friendly EVs, but meeting that demand takes investment on a scale that only companies like BMW and Tesla and Composites Technology (ISSN 1083-4117) is published bimonthly (February, April, June, August, October & December) by Gardner Business Toyota can muster. Media, Inc. Corporate and production offices: 6915 Valley Ave., Cincinnati, OH 45244. Editorial offices: PO Box 992, Morrison, CO 80465. Periodicals Even the i3 is not a guaranteed success, yet, but it has the corporate muscle postage paid at Cincinnati, OH and additional mailing offices. Copyright © 2014 by Gardner Business Media, Inc. All rights reserved. behind it to give it more than a fighting chance, and for that reason, we in the Canada Post: Publications Mail Agreement #40612608. Canada Returns to be sent to Bleuchip International, PO Box 25542, London, composites industry should be glad. ON N6C 6B2 Canada. Postmaster: Send address changes to Composites Technology, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, send Form 3579. Subscription rates: Nonqualified $45 (USD) per year in the United States, $49 (USD) per year in Canada, $100 (USD) per year airmail for all other countries. Single issue prepaid, $10 (USD) per copy in North America, $25 (USD) in all other countries. Send payment directly to Composites Technology at Cincinnati offices, (800) 950-8020; fax: (513) 527-8801. MEMBERSHIPS: CT JUNE 2014 Jeff Sloan 3 Celstran® Thermoplastic Composites The Material for Great Inventions™ If You Think Lighter Can’t be Stronger, Some of the World’s Leading Designers Would Disagree Great imaginations can turn ideas into wondrous inventions, as long as you have the right material. Lightweight. Strong. Stiff. Tough. Celstran continuous fiber reinforced thermoplastic composites (CFR-TP tapes and CFR-TPR rods and profiles) can help you push the envelope on your designs. Strength-to-Weight Properties You’ve Only Dreamed of… Until Now From ground vehicles, oil and gas, aerospace – and everything in between – Celstran continuous fiber reinforced composites open new design space, enabling large-scale lightweighting for demanding component requirements. Tailored to Your Vision With the broadest portfolio of thermoplastic composites in the industry, Celstran tapes, rods and profiles can deliver precise performance to meet your specific design needs and deliver: • Low weight with high strength and stiffness • Superior dimensional and thermal properties • Excellent chemical and corrosion resistance • Eco-friendly processing and recyclability Great Inventions Don’t Happen
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