DAY 1 – 22 August 2023   Body In White & Safety Critical Components

Latest Developments In Sustainable, Lightweight Materials That Are Cost Effective & Scalable For Mass Production While Delivering Optimal Performance & Aesthetics

08:45 Chair’s Opening Remarks

 KEYNOTE PERSPECTIVE – A SHOWCASE FOR INNOVATIVE MATERIALS AND TECHNOLOGIES

SCOPING OUT THE POTENTIAL COST SAVINGS, SUSTAINABILITY BENEFITS & REDUCED ASSEMBLY COMPLEXITY 

08:50 The Future Vision On Large-Part Consolidation For The Body-In-White, Chassis, Subframes & Energy Absorption Systems – Evaluating The Potential Challenges, Trade-Offs & Opportunities

By combining multiple components into a single, integrated structure, manufacturers can reduce the overall weight of the vehicle, improving fuel efficiency, performance, and emissions. This keynote presentation sets the stage for a comprehensive approach to lightweighting and considers the cost benefits, trade-offs, challenges, and opportunities. 

• Highlighting the latest innovations in lightweight materials and manufacturing technologies to serve as a platform for large-part consolidation
• Considering how to manage single-piece structures for the body, body panels, crash management systems, and joining solutions
• Balancing reparability and vehicle design with large-part consolidation approaches to body structure
• Addressing the key challenges – working with the supply chain to make multi-discipline integration happen
• Weighing up cost trade-offs to ensure benefits are realized - while large part consolidation can lead to cost savings in some areas, such as assembly and inventory    management, it can also introduce new costs in other areas, such as material selection or manufacturing processes
• Recycling and end-of-life considerations

The keynote speaker will join the panellists for the Q&A at the end of the keynote panel session 

KEYNOTE PANEL - UNDERSTANDING WHICH MATERIALS TO USE, WHERE, AND AT WHAT COST INTEGRATING SUSTAINABLE LIGHTWEIGHT MATERIALS INTO VEHICLES AT THE DESIGN STAGE

09:15 Material Properties & Selection For High Strength Applications - Balancing Cost, Joining Method Compatibility, Mass Production Feasibility, and End-of-Life Considerations

Benchmarking who is using what to successfully incorporate sustainable lightweight materials into high-strength applications whilst ensuring cost efficiency and production scalability.

Recycled Materials	Recycled, Bio & Natural Carbon Fibre Composites	Magnesium With Improved Mechanical Properties	New Aluminium Alloys & Blends	Hybrid Composites & Sandwich Materials	Bio Composites	Metal Matrix	Development In AHSS & 3rd Gen AHSS
Reduced Weight?	Lower Co2 Footprint? LCA?	Recyclability? End Of Life?	Durability & Longevity?	Cost Of Manufacturing?	Manufacturing Emissions?	Renewable Content Potential?	Strength, Rigidity & Joining
A Pillar B Pillar C Pillar D Pillar	Front & Rear Sub Frames Side Impact	Roof Rails Roof Rigidity Applications	Body Panels Rocker Panels Floor Panels Side Panels	Front & Rear Cross Members	Longitudinal Rails	Floor Cross Members	T Bar

 

09:15 ALTERNATIVE MATERIALS AND DESIGN CHOICES FOR HIGH-STRENGTH BODY IN WHITE APPLICATIONS  Developing New Lightweight Materials & Integrated Joining Solutions That Are Cost Competitive, Scalable For Production & Offer The Necessary Strength, Durability, And Performance Characteristics

- Determining the most suitable sustainable materials for critical body-in-white high-strength applications at the design stage
- Assessing the trade-offs between strength and stiffness requirements in body structures, and the use of cost-effective high-strength materials to reduce weight while meeting safety requirements
- Conducting thorough research and testing to determine the most suitable materials, such as advanced high-strength steel (AHSS), aluminum alloys, or glass fiber-reinforced polymers
- Assessing compatibility between different materials to ensure the desired performance while preventing issues such as galvanic corrosion or uneven thermal expansion
- Conclusions on balancing cost, joining method compatibility, mass production feasibility and end-of-life considerations

Luiz Zamorano Body Engineering, CAD Chief Engineer Ford South America​

09:35 SELECTION OF MULTI-MATERIALS AND DESIGN CHOICES FOR A-PILLAR AND B-PILLAR Material Selection, Design Choices & Joining Solutions For A-Pillar & B-Pillar

This session explores the critical aspects of material selection and joining solutions for A-pillar and B-pillar components in automotive structures. Including a comparison between aluminum vs magnesium vs steel vs the latest innovations in sustainable composites for high-strength applications. 

-  Selecting compatible materials for A-pillar and B-pillar components to achieve optimal performance, safety, and durability, while considering joining techniques and manufacturing processes
-  Comparing aluminum vs magnesium vs steel vs the latest innovations in sustainable composites for high-strength applications
-  Balancing the trade-offs between lightweighting, material choice, and joining techniques to optimize vehicle weight without sacrificing safety or performance and exploring the use of sustainable materials and environmentally responsible practices in A-pillar and B-pillar design
-  Evaluating materials and joining solutions to ensure the highest levels of safety and crashworthiness in A-pillar and B-pillar components, meeting industry standards and regulatory requirements
-  Assessing the economic impact of various material choices and joining techniques, including initial investment, manufacturing processes, and long-term maintenance, while addressing scalability and feasibility in production environment   

09:55 DESIGN OPTIMIZATION FOR MANAGING SIDE-IMPACT AND ROLLOVER/ROOF CRUSH Optimizing Design Choices, Multi-Materials and Joining Techniques for Enhanced Side Impact, Rollover, and Roof Crush Resistance in Lightweight Structure 

-  Choosing materials that offer a balance between sustainability, weight reduction, and mechanical properties such as strength, stiffness, and energy absorption
-  Evaluating the pros and cons of potential solutions including using -advanced high-strength steels (AHSS)
      - Aluminum alloys
      - magnesium alloys
      - composite materials like carbon fiber reinforced plastics (CFRP)
-  Employing suitable joining methods that maintain the structural integrity and performance of the lightweight materials
-  Developing designs that enhance crashworthiness while maintaining weight reduction and sustainability goals
-  Using topology optimization, multi-objective optimization algorithms, and computer-aided engineering (CAE) tools to predict and improve the structural behavior during a crash

10:15 – 10:30 Curated Questions & Discussion

10:30 – 11:00 Networking In The Exhibition Showcase Area
 

LIFE CYCLE ANALYSIS AND CARBON FOOTPRINT REDUCTION

 Optimizing Material Lifecycle Carbon Footprint Analysis and Emission Reduction Techniques

PANEL – MAKING INFORMED DECISIONS ON THE ENVIRONMENTAL IMPACT OF DIFFERENT MATERIALS

11:00 Life Cycle Analysis For Sustainable Architecture Design, Eco-Material Selection & Recycling

11:00 LCA COMPARISON OF LIGHTER STEELS AND ALUMINUM
Comparative Life Cycle Assessment of High-Strength Steel and Aluminum Alloys: Evaluating Environmental Footprints and Material Innovations

11:15 LCA OF DIFFERENT COMPOSITES
Life Cycle Assessment Comparison Between Carbon Fiber Reinforced Polymers, Glass Fiber Reinforced Polymers, & Natural Fiber Reinforced Polymers

11:30 Life Cycle Assessment Of Advanced Magnesium Alloys

Neeshel Dullabh Lead Chassis Integration Engineer Ford Motor Company

Each 15 minute LCA presentation (above) will address the following bullet points Understanding the environmental impacts associated with the extraction, processing, and manufacturing of each material Evaluating the energy consumption, greenhouse gas emissions, and resource depletion associated with each production stage Assessing the environmental impacts during the use phase of the materials, including potential fuel savings, maintenance requirements, and durability, to help provide a more accurate comparison of their overall life cycle carbon footprint Investigating the recyclability and disposal processes for each material to understand their full life cycle impact Assessing the ease of material separation, recycling rates, and the emissions generated during recycling or disposal Conclusions on considering the market availability and cost of each material

11:45 CONSIDERING RECYCLING AND END OF LIFE AT THE DESIGN STAGE Best Practices On Choosing Materials That Are Easily Recyclable & Creating Designs That Allow For Easy Disassembly & Separation Of Components At The End Of Life

-  Conducting a lifecycle analysis to assess the environmental and financial impact of the product’s entire lifecycle, including raw material extraction, production, use, and end-of-life stages
-  Considering the availability and cost of recycling processes for each material and prioritizing those with established recycling infrastructure
-  The benefits of using modular designs with, for example, standardized fasteners, and reversible joining methods
-  Understanding how incompatible materials can increase the cost and complexity of recycling processes or reduce the quality of recycled materials

12:05 EVALUATE THE OVERALL SUSTAINABILITY AND PERFORMANCE OF LIGHTER STEEL Adopting A Cradle-To-Grave Perspective On Advanced High Strength Steel, Ultra High Strength Steel, and Gen 4 Steel, Considering The Entire Life Cycle Of The Material From Raw Material Extraction To Disposal

Providing valuable insight on the carbon footprint and LCA of the latest steel-grades to evaluate the overall sustainability and performance of Gen 4 steel compared to other materials.

-  Understanding of the environmental impact of Gen 4 steel production, including greenhouse gas emissions, water usage, and waste generation
-  Understanding the energy consumed throughout the life cycle of Gen 4 steel
-  Improving resource management practices, reducing costs, and minimizing the environmental footprint of Gen 4 steel production

12:25 THE FUTURE OF SUSTAINABLE COMPOSITES SCALEABLE FOR MASS PRODUCTION Advancing CO2 Neutrality in the Carbon Fiber Industry: Strategies for Enhancing Production Efficiency and Reducing Emissions

How can the carbon fiber industry become more co2-neutral going forward? How effectively can carbon fibers be produced with lower co2 emissions?

-  Conducting a comprehensive LCA to evaluate the environmental impacts of composite materials throughout their life cycle, from raw material extraction to disposal
      -  Innovations in recycling technologies to enable the production of composite materials with recycled fibers, including recycled carbon or glass fibers
      -  Developing carbon fibers from renewable or recycled sources, such as lignin or recycled carbon fibers
            - Natural fiber composites
            - Bio-based resins
      -  Developing efficient and cost-effective manufacturing methods for sustainable composites, such as automated fiber placement, resin transfer molding, and compression molding, can help improve production rates and reduce overall costs
      -  Hybrid composites: Innovations in combining sustainable fibers, such as natural fibers or recycled fibers, with traditional reinforcement materials like carbon or glass fibers to enhance the mechanical properties and overall performance of sustainable composites while maintaining their environmental benefits
-  Ensuring compatibility between different materials used in the vehicle to prevent contamination during recycling
-  Engaging recycling companies and other stakeholders to understand their needs and requirements to identify potential challenges and develop solutions for efficient recycling processes

12:45 – 13:05 Curated Questions & Discussion

13:05 – 14:05 Networking Lunch

 

Evaluating The Key Commercial Considerations For Using Alternative Metals Sustainable & Feasible For Mass Production Understand which materials could be used, where, and what the cost will be

 PANEL – COST REDUCTION STRATEGIES, SUSTAINABLE ALTERNATIVE MATERIALS, AND PRODUCTION EFFICIENCY

14:05 Characterizing Physical Properties & Road Mapping The Development Of Cost-Competitive Manufacturing Processes For Alternative Usage Of Metals & Recycled Aluminium       

 

14:05 USE OF RECYCLED ALUMINIUM Achieving Optimal Performance, Quality, and Cost-Effectiveness in the Use of Recycled Aluminium: Design Choices, Material Selection, and Manufacturing Considerations

 

Where Could It Make Sense To Use Recycled Vs. Virgin Aluminium?

-  Implementing strict material testing and certification processes to ensure that recycled aluminum meets quality and performance standards
-  Developing specialized alloys that are optimized for use with recycled aluminum to help overcome the material's variability and inconsistent quality
-  Accurately characterizing the properties of both recycled and virgin aluminum, including their composition, structure, and mechanical properties, to ensure consistency and optimal performance of the blended material
-  Developing cost-competitive manufacturing processes to accommodate the use of blended materials considering production efficiency
-  Conclusions – where could it make sense to use?

14:25 POTENTIAL USE OF GEN 4 STEEL FOR STRUCTURAL AND SAFETY COMPONENTS  Application Of Gen 4 Steel With A Lower Carbon Footprint & Developing Super-Lightweight Steels That Are Stronger, Cheaper, And As Lightweight As Aluminium

Gen 4 is a new type of steel that provides high strength and durability while being lightweight. Its use could potentially provide long-term cost savings for OEMs for those applications that require high strength, durability, and safety performance.

-  Meeting the performance requirements for the specific application, including factors like strength, stiffness, durability, and corrosion resistance
-  Weight savings:  Assessing the weight savings compared to conventional steels
-  Assessing whether the potential weight savings and performance improvements can offset additional manufacturing costs

14:45 BEST PRACTICE UTILIZATION OF THE LATEST GRADES OF MAGNESIUM FOR STRENGTH AND STIFFNESS Advancing Design, Cost, and Sustainability of Magnesium Alloys: Characterizing Mechanical Properties and Environmental Impact for Next-Generation Manufacturing

Researchers and material scientists continuously develop new magnesium alloys with improved mechanical properties, such as higher strength, better ductility, and enhanced corrosion resistance. How could the next generation of magnesium be used for specific applications while minimizing the need for costly changes in manufacturing and production?

-  Addressing supply chain availability challenges for magnesium
-  Using advanced simulation and modeling tools to optimize magnesium component designs, predict material behaviour under various loading conditions, and identify potential failure modes
-  Innovations in casting processes to allow for the production of complex magnesium parts with improved mechanical properties and reduced porosity
-  Enhancing corrosion protection by developing new surface treatments and coatings that provide better corrosion resistance
-  Combining magnesium with other materials, such as aluminum, steel, or composites to optimize weight reduction while maintaining strength and performance

15:05 Curated Questions & Discussion

15:20 – 15:50 Afternoon Refreshment Break & Networking
 

PANEL – COST-EFFECTIVE APPLICATION OF SUSTAINABLE COMPOSITES  

15:50 Optimal Application & Use Of Sustainable Composites In Vehicle Body Structures Considering Cost Benefits & Production Efficiency

Application of advanced composites for …

                                                                    …  Lightweighting? Design Flexibility? Cost Savings? Regulatory Compliance?

15:50 APPLICATION OF GLASS FIBER COMPOSITES FOR STRUCTURAL COMPONENTS  Optimizing the Application & Production Of Glass Fiber Composites: Balancing Manufacturing Complexity, Applications, and Cost Considerations

-  Assessing the cost implications of using high-strength sustainable materials, including raw material costs, manufacturing costs, and any additional expenses associated with the processing or joining techniques
-  Considering factors like formability, machinability, and any specific processing requirements for each selected material
-  Evaluating the strength, stiffness, durability, and other relevant properties of potential materials to ensure they meet the required performance criteria for each structural application
-  Ensuring compatibility between different materials in the vehicle structure to prevent issues like galvanic corrosion or reduced structural integrity

16:10 ADVANCED MODELLING COMPOSITE MATERIAL PROPERTIES Accelerating The Development And Adoption Of Advanced Modelling Tools And Techniques To Simulate The Performance Of Composite Materials In A Full Vehicle Context

Accurate modeling of composite materials at an early stage of vehicle development is crucial for building confidence in their appropriateness for both structural and non-structural applications.

-  Implementing modelling techniques to accurately capture advanced composite properties, especially in dynamic loading scenarios
-  Simulating the performance of the materials in a full vehicle context
-  Advanced software tools and techniques for modeling composite materials, such as finite element analysis, optimization, and virtual testing
-  Integrating composite material models with other vehicle components and systems
-  Understanding the manufacturing process and its effect on material properties is essential for modeling and simulation
-  Comparing simulation results with physical testing data

16:30 OPTIMIZING THE USE OF RECYCLED FIBERS IN COMPOSITE MATERIALS Balancing Cost, Sustainability, and Performance Considerations When Using Recycled Fibers In Composite Materials for Body Panels, Chassis Components, and Structural Reinforcement

What is the potential loss of mechanical properties due to fiber damage during the recycling process?  And how can this be cost-effectively mitigated?

-  Accurately characterizing the properties of recycled glass fibers, including their compatibility with other materials in the composite, to determine the ideal fiber content and orientation for achieving desired mechanical properties and performance
-  Developing and refining manufacturing methods to ensure consistent quality and performance of the composite materials incorporating recycled glass fibers
-  Rigorously testing and validating the performance of recycled glass fibers to ensure they meet required specifications and safety standards, including strength, stiffness, and impact resistance, for their intended applications in body panels, chassis components, and structural reinforcements

16:50 MANUFACTURING PROCESS FOR SUSTAINABLE COMPOSITES Innovating Manufacturing Processes To Scale Up The Production Of Sustainable Composites To Lead To Increased Production Efficiency And Lower Costs

-  Managing the unique properties of sustainable materials, such as moisture sensitivity, to manage challenges during manufacturing
-  Examining potential solutions, including controlled storage environments, proper material conditioning, and optimized handling techniques
-  Manufacturing process optimization
-  Material and process standardization
-  Integrating automation and digital technologies into the manufacturing process to improve production efficiency, consistency, and quality

PANEL – APPLICATION OF SUSTAINABLE MATERIALS FOR NON-STRUCTURAL COMPONENTS

17:15 Application Of Sustainable Materials For Exterior Trim & Non-Structural Components

Bumpers & Energy Absorption	Outside Trim	Doors & Interior Panels	Hood & Trunk
Recycling Thermoplastics	Biodegradable Polymers	Natural Fiber Composites	Bioplastics

17:15 MATERIALS FOR THE BUMPER Pathways For Improving The Recyclability of Fiber-Reinforced Thermoplastics

Fiber-reinforced thermoplastics offer the potential for lightweight and improved performance compared to traditional materials, making them an attractive option for the automotive industry as it seeks to reduce vehicle weight and improve fuel efficiency. This session looks at pathways for recycling fiber-reinforced thermoplastics more efficiently and sustainably, leading to the production of more environmentally friendly composite materials for the automotive industry.

- Examining the latest recycling technology innovations to effectively reclaim fibers and the thermoplastic matrix for reuse in new composite materials, including
       - mechanical grinding
       - solvolysis
       - pyrolysis
       - Evolving manufacturing processes for producing new composite materials using recycled fiber-reinforced thermoplastics, taking into consideration material properties, design requirements, and production efficiency
- Efficient methods for separating and sorting fiber reinforcements from the thermoplastic matrix
- Ensuring the recycling process maintains the mechanical properties and performance of both the fibers and the thermoplastic matrix, as these properties may degrade  during recycling
- Accurately characterizing including their compatibility with virgin materials and with each other, to ensure the desired performance and quality of the new composite materials

17:35 BIODEGRADABLE POLYMERS FOR NON-STRUCTURAL COMPONENTS Achieving Mechanical Performance in Biodegradable Polymers For Non-Structural Exterior Components To Deliver Weight Savings

Biodegradable polymers are designed to break down over time, which can affect their mechanical properties. The rate and extent of degradation can vary depending on factors such as temperature, moisture, and the presence of microorganisms.

-  Achieving the necessary mechanical performance for automotive applications
-  Assessing processing and manufacturing innovations

17:55 Questions & Discussion

18:15 Chair’s Closing Remarks

18:20 Networking Drinks Reception