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Archived Automotive Sector News - 2007
Editors - please refer to the Notes to Editors for background information on Umeco plc and its operating divisions.
Record Breaker uses ACG's Fast and Flexible Prepregs to Lose Weight
Production of Koenigsegg CCX Body-In-White
Mass Production Compression Moulding Logistics
Street Legal and More Sleek Horses to the Kilo with ACG's BPS - Ascari's A10
Automotive Support Team Distinguishes ACG from the Competition
High Volume Applications Proved Viable
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By now pundits will be well aware of the outstanding performance of the Caparo T1. While this car is road legal it is clearly aimed at the true enthusiast, giving them the chance to own a car that provides the closest experience possible to an open racing car, and at an affordable price.
The Caparo T1, which is now in production at the Caparo Basingstoke UK facility, weighs less than 500kg and the engine develops in excess 500bhp.
The resultant 1,000bhp/tonne power-to-weight ratio endows the car with an extraordinary 0-60mph time of 2.5 seconds, a 0-100mph time of 5 seconds, and a 0-100-0mph time of less than 10 seconds, thus making it the world's fastest accelerating and braking road car. It is also fast round corners, with 3g cornering ability that is equivalent to a Le Mans Prototype.
Advanced Composites Group has supported the T1 vehicle development from the beginning of the project. Caparo initially used 3k woven carbon with LTM®23 resin for low temperature cured prototypes off soft moulds, a strategy which significantly reduces development costs and timescales. The tooling and the parts were then refined in tandem with the engineering design of the vehicle. ACG's LTM®212/CF0300T and LTM®212/CF0700T tooling prepregs were used for the production tools, producing enhanced, dimensionally accurate production moulds that facilitate vehicle manufacture.
ACG worked directly with Caparo to optimise the lay-up and production materials for the vehicle structures. The production vehicle structures now utilises ACG's MTM®58FRB predominantly with 400gsm 12k woven fabric. This has both technically simplified the manufacturing process and reduced the cost of the assemblies.
MTM®58FRB was developed and formulated specifically for automotive structures. It offers a 140°C Tg, is self-extinguishing to FMVSS302/ISO3795 and exhibits excellent drape and tack. In addition, it has the ability to impregnate high aerial weight fabrics and affords good impact resistance. MTM®58FRB was also developed with high production volumes in mind, which is an important aspect of Caparo corporate strategy. This approach will aid the introduction of carbon fibre composites parts into high volume automotive applications where fuel efficiency is increasingly becoming a design driver.
Caparo Vehicle Technologies are part of the Caparo Vehicle Products Group. Their CEO, Richard Butler, explains that composite materials are part of an integrated automotive and aerospace strategy, which includes braking, lightweight metallics, fastenings and tube components that provide OEMs with an unsurpassed selection of lightweight technologies. A key element to Caparo's plans, both in the UK and worldwide, is to provide low cost production capabilities. This approach will ensure that advanced composites solutions can be put into full production at affordable prices.
Image courtesy of Caparo Vehicle Technologies
Advanced Composites Group
Jon Stowell – Sales and Marketing Director
Telephone: +44 (0)1773 766200
Peugeot Reveals New 308RC Z - November 2007
As it prepared to launch its new 308 compact range across Europe, Peugeot lifted the covers on a 308-based concept for the Frankfurt auto show that suggests the French automaker may be considering a potential competitor to the Audi TT.
Called '308RC Z', the 2+2 coupe shares many of its mechanical underpinnings with the new 308 hatchbacks that were distributed to European dealers in August.
The coupe design appears to be nearly production-ready, although it is not clear if Peugeot would build the vehicle as a fixed-roof coupe or a coupe/convertible with retractable hardtop.
Continuing the developing trend for lighter weight vehicles and the increasing use of ACG composites in the market place, Peugeot has developed a carbon fibre roof for the vehicle, significantly reducing the vehicle weight and improving the vehicle dynamics by lowering the vehicle roll centre.
The roof, which is manufactured by Application Composites (Monereau-sur-le-Jard, France), is moulded using ACG's MTM®57 resin system, which is renowned for its clarity and technical performance on cosmetic finished components. The MTM®50 resin series offers superb drape and pre-forming tack levels with short cure cycles, which combine to make it suitable for matched die press moulding processing and, therefore, high volume automotive production. The flexible cure cycles also allow this resin series to be used for autoclaved or oven-cured low volume or prototype parts.
ACG's MTM®50 series resin systems are becoming the automotive standard for cosmetic and structural automotive applications, with the series already being used on many European OEM vehicles.
Powering the 308RC Z is a high-output version of the twin-cam, direct-injection, four-cylinder petrol engine that was jointly developed with PSA and BMW. The turbocharged 1.6 litre engine provides 218 horsepower and 221 pound-feet of torque, and is complemented by a newly designed, six-speed manual gearbox.
Image courtesy of PSA Peugeot Citroen Automobiles
For further details contact ACG Sales Department.
Record Breaker uses ACG's Fast and Flexible Prepregs to Lose Weight - April 2007
The record breaking JCB DIESELMAX established the new 350.092mph (563.418kmh) milestone for diesel cars on its first attempt at Bonneville in late August 2006.
The relatively short Bonneville track requires fast acceleration as well as record top speeds, so it was important to keep the car as light as possible. The core requirements for a successful land speed record attempt are an incredible engine, aerodynamic stability, chassis control and very low vehicle mass. Visioneering, a complete one-stop design, development and engineering company based in Coventry in the UK, designed the complete vehicle structure and exterior body on the basis that carbon fibre would be used in the manufacturing process.
Because of their fast lay-up times, flexible cure cycles and excellent mechanical properties, ACG’s BPS240 ZPREG® carbon fibre composite body panel material was used for the exterior skin while its VTM® range of materials were used for the vehicle tub and other structural applications. Close teamwork from the technical partners was the critical factor to develop such a successful car in such a short time.
Externally, JCB significantly increased its public profile from the project, having been able to demonstrate that the new JCB444 engine is capable of incredible performance and that they also make their own engines. Internally, JCB's employees have taken great pride in the achievement and have found the DIESELMAX project motivating for their own projects. There has also been considerable engineering learning on the engine, which they expect to influence their future product strategy.
This project has proved ACG’s materials in a harsh structural environment, allowing the engineers and moulders to produce such a record breaking vehicle in record breaking time.
For more information visi www.visioneering.ltd.uk
Image courtesy of JCB Dieselmax.
Advanced Composites Group
Jon Stowell – Sales and Marketing Director
Telephone: +44 (0)1773 766200
Production of Koenigsegg CCX Body-In-White - April 2007
As the use of composites increases in the Automotive Sector, the integration of production techniques with material selection is essential to meet the cost targets demanded by OEM’s. Devising a competitive process for full scale production of an all composite car is the major challenge facing moulders of automotive composite components today.
Building on their involvement with the McLaren-Mercedes SLR project, Smiths Aerospace, based in Hamble-le-Rice, Hampshire UK, have now embarked upon full scale production of the Koenigsegg CCX Body-In-White.
Just a decade after the launch of the original CCR sees the emergence of the CCX, the latest update to the car that broke the world speed record. The CCX has been re-engineered to comply with US crash regulations and now includes a new composite carbon fibre chassis, carbon fibre bodywork and an updated engine that was developed in-house.
ACG was instrumental in the initial re-engineering of the project, manufacturing tooling and several pre-production prototype body kits at its UK base. However, for large-scale commercial production of the car, a company with a manufacturing facility was required. Facing stiff international competition, Smiths were eventually selected as manufacturer by Koenigsegg and immediately set to work on a costdown programme for the car.
A thorough review of material options was undertaken in collaboration with ACG engineers. A solution based around ACG’s MTM®58FRB was selected for the chassis and structural components, as this system offers the best balance between performance and competitive pricing. ACG’s BPS240 carbon body panel system was selected for the bodywork.
Both systems offer the flexibility of curing under vacuum-only conditions, thus enabling Smiths to optimise work flow through their plant. All prepregs were nested onto Smiths’ XY CNC cutting machines at the earliest opportunity, giving optimum material usage with a fixed bill of materials for order placement purposes. This resulted in efficient materials scheduling into their plant for the duration of the contract, together with enhanced quality control of the moulded components.
All finished mouldings are also CNC machined on Smiths’ 5-axis milling machines, thereby minimising labour input while also increasing repeatability. Smiths also assembles the chassis and panels to Body-In-White standard, providing instant feedback on any engineering issues that needed to be addressed on-line, again giving their customer the advantage of an entire turn-key package.
Image (Koenigsegg CCX) courtesy of Koenigsegg Automobile AB.
For further details contact ACG Sales Department.
After two seasons of racing and development, capitalising on relationships with internationally competitive MT900 race teams, the MT900S has emerged as an exciting prospect for the enthusiastic road user.
Weighing in at 1150kg (2,535 lbs) and powered by a mid-mounted 435bhp V8 from the Corvette Z06, this ultra-light, low volume
supercar from the USA sets new performance standards by delivering a uniquely exhilarating driving experience.
The US road legal supercar meets all of the strict US safety standards and boasts an incredibly strong roof structure, resulting in the highest rollover protection observed by the General Testing Laboratories.
The primary vehicle monocoque structure is manufactured from carbon fibre and presents a striking exterior. RTN, which operates in Norfolk - UK, uses ACG’s carbon fibre BPS240 body panel system to make the front and rear clamshells from high quality, low cost tooling.
BPS240 is a ZPREG® rapid deposition system with a stable, high temperature and integrated surface film capable of producing ‘Class A’ surfaces that can be maintained during the service life of the component. RTN has taken full advantage of BPS240’s
enhanced moulding capabilities, excellent stable surface quality, processing benefits and cost savings over traditional and prepreg materials.
Image (Mosler MT900S) courtesy of Breckland Technology Limited.
For further details contact ACG Sales Department.
Mass Production Compression Moulding and Logistics - March 2007
Polytec Group (Austria) have nominated ACG as their chosen composite materials partner because of the company's 30 years of composite application development experience in the automotive industry. It has been clearly recognized that ACG's extensive technical support capability, covering functions from design to process engineering, will help Polytec ensure advanced composite material choice is always optimized both for performance and for cost.
In consultation with ACG, and as part of an on-going cost reduction and quality improvement programme for Porsche on the Carrera GT, Polytec Composites (Sweden) have converted the manufacturing process for several carbon fibre components (originally conceived as oven or autoclave cured) to rapid press moulding and, in the process, have realized significant cost and quality advantages.
Ultimately for the Carrera GT, Polytec supplies parts that are oven, autoclave and press moulded. To service this requirement, ACG supplies twelve different formats of material, all of which are automatically configured into a total of 183 unique templates and then packaged into car-kit sets. Nesting is optimized and material kits are delivered on a JIT basis to Polytec Composites in Sweden, keeping the supply as lean and cost effective as possible.
Polytec's proactive flexible engineering approach, and their production manufacturing expertise, continues to be used to great effect on other projects and allows them to offer composite parts using a variety of different composite processing technologies. ACG continue to support their activities, providing guidance on optimum design and manufacturing processes, as well as materials specification.
For further details contact ACG Sales Department.
Street Legal and More Horses to the Kilo with ACG's BPS - Ascari's A10 - April 2007
Following on from the successes of Team Ascari Racing in the LMP1 class, the KZ1 was shown as a supercar concept in
October 2000.
The production road car that followed has received an enthusiastic response from the motoring press. They have been particularly impressed with its composure, both on the road and on the track; in 2006, it was the winner of the EVO magazine road and track group test, beating some established supercar manufacturers. The normally-aspirated 5 litre V8, 32 valve engine effortlessly provides 500 brake horsepower through a six speed manual gearbox to the rear wheels.
The KZ1 road car is the basis for the successful KZ1 GT3 that races in FIA and British GT3. The carbon fibre monocoque structure provides lightness and strength to the sleek, mid-engined design, resulting in a drag coefficient of just 0.39. The beautifully designed and sculptured class ‘A’ exterior is made from ACG’s BPS240, BPS240 is a two-ply ZPREG®, partially impregnated epoxy prepreg system, designed for the manufacture of exterior body panels. It provides excellent surface quality from vacuum-bag or matched die press-moulding at cure temperatures between 85°C to 180°C (185°F to 365°F).
This robust material format provides consistent tack, excellent drape and conformation. BPS240’s ZPREG material architecture is designed for reliable air-removal and excellent panel flatness and rigidity. The high performance resin systems were designed for service temperatures up to 160°C (320°F), and give excellent physical and environmental performance for painted automotive applications. The material is available as standard in carbon and glass fibre variants, in rolls or pre-cut kits. The material complies with the automotive flame retardant specification FMVSS302 and is recommended for use with high quality composite or metallic tooling. Moving swiftly on to yet another successful ASCARI super car project involving ACG materials, we see the A10 model that took to the road in the Summer of 2006. The A10 has 620 brake horsepower and weighs in at around 1250kg, thanks to its light-weight carbon fibre bodywork. The body panels of this car are manufactured by Universal Race Technology (URT) using ACG’s BPS240 body panel material. Unlike the Ferrari Enzo FXX, which is produced exclusively to be driven only on track days and costs just over £1 million, Ascari’s engineers are committed to ensuring that this 220mph super car delivers another stunning vehicle that is road legal and can be driven home and parked on your drive.
Image (Ascari A10) courtesy of Ascari Cars.
For further details contact ACG Sales Department.
Automotive Support Team Distinguishes ACG from the Competition - February 2007
Advanced Composites Group Ltd. specialises in the manufacture of high performance composite materials and offers a unique one-stop-shop for composite technology, combining extensive 
materials manufacturing capability with an unrivalled in-house design and production base.
Many new composite and hybrid vehicle launched during 2002 and 2003 used ACG's composite materials. This highlights the significant processing and performance advantages of ACG's materials over the competition and the level of customer support that ACG's automotive team offers. Seen here is the Peugeot Hoggar 4x4 wheel concept car that was designed and built by PSA Group Design Centre in La Garenne. The entire carbon body is made from ZPREG® and structural components from ACG prepreg.
ACG adds a unique combination of technologies, process expertise, logistic support and automotive engineering to its customers worldwide, having been at the forefront of composite technology for over 20 years and is well established as the world's leading supplier of both the technology and materials into the motor racing industry.
Having introduced the first carbon composites into motorsport in the 1970s and then developed the now accepted approach to manufacture integrated carbon composite monocoques in the 1980s, ACG has subsequently designed, developed or manufactured over 700 road and race car chassis.
ACG's continual material and processing developments offer genuine automotive solutions to the industry's complex engineering and commercial challenges that result directly in superior vehicle performance, significant fuel economy and programme cost savings.
Image (Hoggarth 4 x 4) courtesy of Peugeot.
For further details contact ACG Sales Department.
Lower Automotive Emissions - January 2007
As part of the continual drive for better fuel economy and lower emissions, ACG was tasked by one of the largest European OEMs to produce a detailed feasibility study on a structural bulkhead to show that advanced composite structures were both technically and commercially feasible for production volumes up to 30,000 parts per year.
The OEM set aggressive technical targets focusing on significant weight reduction and increased performance, all for a comparable piece price.
Material specification and correlated performance simulation is key to the rapid composite engineering solution and essential for the OEMs. Material selection, choice of manufacturing process, design-for-manufacture and the use of automation where necessary in the manufacturing process, are key for controlling the costs.
Employing ACG's extensive product portfolio and volume processing experience, combined with P&Z Engineering's computer modelling and vehicle engineering experience, the design was optimised iteratively. A turnkey design and processing solution was developed, refined and presented by ACG's engineering team only a few weeks later.
The final solution offered significant mass reduction, and torsional performance with associated improved NVH damping characteristics. With the adoption of suitable automation during the manufacture process, equivalent part price could also be maintained. With ACG having shown that the technical and commercial targets could be achieved, the OEM is currently considering the next steps.
For further details contact ACG Sales Department.
High Volume Applications Proved Viable - January 2007
ACG's LTM®26 prepreg resin system is used extensively within the automotive industry worldwide for the production of components requiring high aesthetic appearance, resin clarity and excellent mechanical performance.
The system has undergone thorough UV and weathering qualification testing, providing exceptional results when compared with other structural epoxy resin systems. Amongst LTM®26's numerous applications is its use for bumper extensions as part of the advanced aerodynamics pack on the BMW 3 Series. The bumper extensions are manufactured by Die Wethje (Hengersberg, Germany), who were very careful both in their selection of composite materials and in the moulding process used for the components.
LTM®26 prepreg is also the material of choice for the interior trim package on the Jaguar X Type Sport. These components are manufactured by EPM Technology (Draycott, UK).
The fact that LTM®26 prepreg can be used cost effectively on such significant 'production' quantity production volume applications runs contrary to a commonly held misconception about the commercial viability of advanced composite materials for high volume automotive applications.
For further details contact ACG Sales Department.
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