Archived Automotive Sector News - 2008

Editors - please refer to the Notes to Editors for background information on Umeco plc and its operating divisions.

ACG Shares Performance and Customisation ‘Finalist Award’ with Plasan for MTM®57 Prepreg Application on GM’s 2009 Corvette ZR1

New ACG BPS240-Clad IFR Automotive ‘Aspid’ Luxury Sports Car Unveiled

Koenigsegg ‘Edition’ in Virgin Carbon Fibre

Farbio GTS Sporting ACG’S BPS240

Other News	2009	2007	Older
Automotive

ACG Shares Performance and Customisation ‘Finalist Award’ with Plasan for MTM®57 Prepreg Application on GM’s 2009 Corvette ZR1 - December 2008

At the 2008 SPE Automotive Innovation Awards, Advanced Composites Group Ltd (ACG), a member of the composites division of Umeco plc, shared an important ‘Finalist Award’ for the proficient application, by Plasan Carbon Composites Inc, of ACG’s MTM®57/CF3238 carbon fibre prepreg material for the manufacture of the carbon fibre composite roof assembly on General Motors’ 2009 Corvette ZR1.

GM’s preferred composite components supplier, Plasan, uses ACG’s MTM57 carbon fibre prepregs and associated products to manufacture the ZR1’s virgin carbon-fibre roof, roof bow, rocker extensions and front air splitter. The award describes the roof application as “A proprietary, UV-stabilized and colour corrected clear coat was developed to prevent yellowing of exposed-weave carbon fibre composite in this highly visible, Class A roof assembly with exacting aesthetic requirements. Replacing an earlier thermoplastic roof assembly, the bonded advanced composite version is lighter (lowering the vehicle’s center of gravity), has lower coefficient of linear thermal expansion (CLTE), and is more robust, providing improved rollover protection.”

Not limited to just the roof assembly, the ZR1 combines the latest automotive technology with even more ACG carbon composite prepreg material applications to reduce vehicle mass and offer improved fuel economy and reduced emissions. Other significant parts on the limited availability ZR1 that use ACG’s MTM57 prepregs include the front air splitter, which works in conjunction with the rear spoiler to form a superior aerodynamic pack that provides enhanced stability at high speeds. Like the composite roof assembly, the splitter features the special clear coat that resists weathering and destructive UV rays, whist also imparting that essential, excellent, aesthetically pleasing, clear cosmetic carbon finish. Combine the aerodynamic pack of front fascia splitter and rocker mouldings with the ZR1’s award-winning lightweight roof construction and the ZR1 gamely sprints to 205mph on the test track.

ACG’s superior MTM57 component prepreg is based on a 120°C (248°F) curing epoxy resin matrix, exhibits excellent toughness and can, after a suitable cure, be used at temperatures up to 90°C (194°F). Whilst MTM57 offers versatile processing options such as autoclave, vacuum bag or press moulding, Plasan employs the latter to obtain that essential cosmetic, aesthetically pleasing surface finish and maximum component throughput.

The launch of the 2009 ZR1 comes two decades after Corvette and Lotus originally joined forces to fashion this ferocious machine. With a powerful engine (405 horses), dynamic active suspension and streamlined form, the original ZR1 formed a new standard in the mega performance sector, leaving the competition in its wake at every turn.

Following what seems like an age of conjecture, the ZR1 has returned. Now, the 2009 ZR1, fully adorned with ACG’s MTM57 advanced carbon fibre prepreg, is set to be the fastest, most exclusive, limited production Corvette – affectionately referred to as the ‘Vette’ - ever seen. With ACG’s prepreg materials playing their part in GM’s weight reduction programme, and a furious ‘heart’ - a ‘four lobe’ rotor design supercharger fed race tuned 6.2 litre V8  engine - delivering an astounding 638hp, the ZR1 is set to take the world by storm, or at lease cause it to rotate even faster than nature intended!  Topped with a clear hood window to show off the hardware, with a body style created for pure aerodynamic performance, and lustrous, dark and aesthetically pleasing cosmetic carbon components, the ZR1 ‘Vette’ will turn every head on the block.

European delivery is anticipated to be towards the end 2008, but with severely limited availability.

Image: Copyright Advanced Composites Group Ltd

For further details contact ACG Sales Department.

New ACG BPS240-Clad IFR Automotive ‘Aspid’ Luxury Sports Car Unveiled at British International Motor Show - July 2008

Advanced Composites Group Ltd. (ACG), part of the Composites Division of Umeco plc, is pleased to announce that the long awaited IFR Automotive ‘Aspid’ sports car, which made its debut at the British International Motor Show in London on the 22nd July 2008, has made extensive use of the Group’s distinctive BPS240 Body Panel System and superior MTM®57 component prepregs.

The Aspid is a new, technically-advanced luxury sports car from automotive engineering consultancy IFR Automotive.  The Aspid offers exceptional performance, agility and style in a small, lightweight and ultra compact package.

The Aspid is the only car in the world to meet both FIA safety requirements and European homologation standards.  This means it already has the strength within its hybrid carbon fibre and aluminium body structure to avoid the need for an additional roll cage; it really can be driven from the road directly onto the race track without the need for any special preparation. 
A thorough review of composite material options was undertaken in collaboration with engineers from ACG. ACG's BPS240 carbon body panel system was selected for the bodywork and MTM®57 was selected for the trim applications.  The interior trim applications were press moulded with aluminium tools, giving excellent surface finish and high part-to-part dimensional tolerances with minimal trimming operations.

ACG's carbon fibre composite BPS240 Body Panel System has become the material of choice for painted carbon body panels throughout the automotive industry, and was approved by IFR Automotive in early 2008. BPS240 is a ZPREG® rapid deposition system with a stable, high temperature and integrated surface film capable of producing ‘Class A’ surfaces for both low and high bake paint systems, while also having the ability to maintain this standard in service.

BPS240 panels can be moulded from high quality composite or metal tooling, reducing manufacturing times by as much as 80% compared with traditional carbon prepreg materials. Further significant cycle time and cost reductions are available if the material is processed using matched die compression moulding techniques, as IFR have used for the interior parts.

MTM57 offers one of the best solutions in the industry for cosmetic trim applications, giving a fully transparent clear surface finish with excellent UV performance.

The predominance of carbon fibre in the vehicle has allowed IFR Automotive to reduce vehicle mass to just 700kg (1,550lb).  This has two effects, the first being to reduce vehicle emissions, while also increasing fuel economy, and the second is to bestow it with exceptional performance figures; a 570bhp-per-tonne (1.75kg/bhp) power-to-weight ratio, 0 - 62mph (100km/h) in 2.8 seconds and 100mph (160km/h) in 5.9 seconds, with equally impressive braking performance from 100 to 0mph in 3 seconds.

Image/Photograph: ‘Credit IFR Automotive’.

For further details contact ACG Sales Department.

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Koenigsegg ‘Edition’ in Virgin Carbon Fibre - March 2008

ACG continues its rewarding association with Koenigsegg by supplying MTM®57, a flexible component composite carbon fibre prepreg system, for a limited number of its special ‘Edition’ CCX and CCXR sports cars.

The exclusive nature of these special ‘Edition’ sports cars took the ‘standard’ cars, if you could ever call them that, to a new level when they were launched at the March 2008 Geneva Motor Show.

Just twenty of the special ‘Edition’ versions are being built, sixteen based on the CCX model and four based on the CCXR (E85/petrol flex fuel) model, both of which feature a 5.0L twin supercharged Koenigsegg engine, delivering 888bhp and 1018bhp respectively. While supplies will be severely limited, performance certainly is not! With acceleration quoted as being 0-100 km/h (0-62 mph) in 2.9 seconds and a top speed 417+ km/h (250+ mph), there’s definitely nothing remotely ‘limiting’ about these cars!

The distinguishing feature that makes Koenigsegg’s ‘Edition’ variants stand-out from their ‘standard ’ CCX and CCR counterparts is the shimmering virgin carbon fibre finish. While the ‘standard’ versions use ACG’s composite carbon fibre prepreg Body Panel System BPS240 for the sleek and stylish painted body, the ‘Edition’ versions use ACG’s MTM®57 composite carbon fibre prepreg (pre-impregnated) material to give that distinctive carbon appearance.

So, what you really see is that exquisite mixture of a carbon fibre weave and the specially formulated resin matrix right there on the surface of this sleek and stylish, world-class ‘Edition’ sports car. MTM57, just one of ACG’s composite carbon fibre component prepreg materials, exhibits excellent toughness and can be processed using autoclave, vacuum bag and press techniques. As will be evident on the Edition sports cars, the surface finish achievable with this prepreg is second to none.

Built more as track-based sports cars, the Edition versions have stiffer springs and anti-roll bars, reset dampers and a lowered chassis. They also feature a large adjustable rear wing, larger front splitter and side strakes for increased down force and a unique ‘forged’ wheel design.
All of Koenigsegg’s CCX and CCR sports cars (both ‘standard’ and ‘Edition’) use ACG’s MTM®58FRB for the chassis, under-bonnet and structural components. What you experience here is the amalgamation and application of products that are the result of a long-term partnership between ACG and Koenigsegg, one that started at the initial engineering stage of the CCX project.

ACG assisted with the manufacture of tooling and several pre-production prototype body kits at its UK base. However, large-scale commercial production of the car is handled by Hampshire-based GE Aviation (formerly Smiths Aerospace), which is renowned for its involvement in the McLaren-Mercedes SLR project, amongst others.

The ‘standard’ CCX and CCR models are only available in painted livery. ACG’s BPS240 composite carbon fibre prepreg Body Panel System is employed for the sleek, stylish and sculptured body panels. BPS240 is a two-part, partially-impregnated epoxy prepreg system designed for the manufacture of body-in-white panels. It provides excellent surface quality from vacuum-only or press moulding.

The first ply of BPS240, which utilises ACG’s ZPREG® partial impregnation technology, consists of a structural fabric coupled to a surface scrim by a high performance resin system. The second ply combines low density syntactic core material and a structural fabric to create significant panel rigidity in a rapid laminating format. The system is designed to be ready for painting without additional surface rework. In many cases, paint can be applied directly to a degreased panel. Excellent environmental performance can be expected from panels painted in Low-Bake and Hi-Bake paint systems.

All prepreg systems used for Koenigsegg’s CCX and CCR models offer the flexibility of curing under vacuum-only conditions, thus optimising work flow through GE Aviation’s manufacturing plant. GE, which has significant experience in the exclusive sports car market, is responsible for full-scale production of the CCX body-in-white.

At GE’s Hamble facility in Hampshire, all prepregs are nested onto 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 5-axis milling machines, thereby minimising labour input while also increasing repeatability. GE also assembles the chassis and panels to Body-In-White standard, providing instant feedback on any engineering issues that need to be addressed on-line, again giving their customer the advantage of an entire turn-key package.

Proof of reliability and Koenigsegg’s demonstrable confidence in the ‘Edition’ versions is delivered in an all inclusive 5-year free service and warranty package.

Photos courtesy of Koenigsegg Automotive AB.

For further details contact ACG Sales Department.

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Farbio GTS Sporting ACG’S BPS240 - March 2008

ACG applies its BPS240 ZPREG® rapid deposition system to great effect on the Farbio GTS.

Having a space-frame chassis completely clad in ACGs BPS240 carbon fibre body panel system, the Farbio GTS generates a power-to-weight ratio of 366bhp per tonne. However, it’s not all down to the materials; some credit must go to the supercharged version of the well-proven Ford 3-litre V6 Duratec engine, which produces 384bhp, and to the low cumulative mass of the vehicle, which is just 1066kg.

This equates to a 0-60mph time of 3.9 seconds, eclipsing the performance of both the Ferrari F430 and the Lamborghini Gallardo. This is particularly impressive when you realize that the price of this stunning sports car is around half that of the Ferrari or the Lamborghini.

The GTS has come a long way since its appearance at the 2004 Birmingham motor show. Significant vehicle engineering development, body construction refinement, composite material developments and new tooling have been combined to enable the GTS development team, led by Chris Marsh, to engineer and deliver a British sports car with an £22M order book.
ACG’s BPS240 is a ZPREG® rapid deposition system, with its stable, high temperature and integrated surface film is capable of producing ‘Class A’ surfaces, while also maintaining them in service. BPS240 offers enhanced moulding capabilities, excellent and stable surface quality, effective processing benefits and a significant cost saving over traditional prepreg technologies. BPS240 panels can be moulded from high quality, low cost composite tooling, thereby reducing manufacturing times by as much as 50% compared with traditional advanced composite materials.

ACG, which is the leader in continuous fibre material technologies into the mainstream Automotive Industry, offers a full turnkey application development package from concept design, through prototype manufacture, process optimisation and production support at the production mould stage.

ACG continues to work with OEMs and their suppliers to develop composite automotive applications, including: full vehicle structures, closures, fully paintable exterior body panels and exterior trim, seat structures and interior trim, all of which save weight, reduce the total programme cost, help to meet emission and safety requirements and enable unprecedented functionality.

Photos courtesy of Flow Images.

For further details contact ACG Sales Department.

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Other News	2009	2007	Older
Automotive