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Archived Automotive Sector News - 2011
Editors - please refer to the Notes to Editors for background information on Umeco plc and its operating divisions.
New Delta Motorsport E-4 Coupé Takes Centre Stage on the Umeco Composites Stand at JEC 2011
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Advanced Composites Group’s Prepregs Used On GTA Motor’s ‘Spano’ Super Sports Car - 5th December 2011
Tooling, automotive body panel system and high visual quality prepregs manufactured by Advanced Composites Group, a member of Umeco Composites Structural Materials (UCSM) – a division of Umeco plc., are being used by Spanish car manufactured GTA Motor to create their exclusive ‘Spano’ super sports car.
Designed for GTA Motor’s owner Domingo Ochoa by their engineering director Sento Pallardó, the GTA Spano boasts advanced material technology, innovative aesthetics, superior aerodynamics, futuristic solutions and established application techniques. ACG’s cost-effective Out-of-Autoclave (OoA) materials and expertise have played a significant role in making Domingo Ochoa’s dream a reality, enabling them to compete with international prestigious brands both in terms of image and performance.
GTA decided to use material with a proven track record of successful application to manufacture the 99 units of their Spano super sports car. ACG’s OoA LTM®217 prepreg and compatible LTF318B surfacing film have been selected for the tooling, BPS240 body panel system for the bodywork, and a combination of ACG’s LTM®24ST and LTM®26EL high visual quality cosmetic prepregs for the interior and exterior cosmetic trim panels. For high impact resistance in certain areas of the car, GTA Motor is using ACG’s VTM®264 resin system on a hybrid aramid/carbon reinforcement.
BPS240 is ACG’ two-ply, partially impregnated, oven/vacuum bag processing, epoxy prepreg system specifically designed for the manufacture of body-in-white panels with excellent surface quality from vacuum-only processing at cure temperatures between 85 to 150°C. The first ply utilises ACG’s ZPREG® partial impregnation technology, which consists of a structural fabric coupled to a surface scrim and a high performance resin system. The second ply combines low-density syntactic core material and structural fabric to create significant panel rigidity, and all delivered in a rapid layup format. BPS240 is designed to be ready for painting with minimal preparation. In many instances, paint can be applied directly to a degreased panel taken straight from the mould tool. Moreover, excellent environmental performance can be expected from panels painted in Hi-Bake & Lo-Bake paint systems.
ACG’s LTM®217 tooling prepreg offers GTA Motor the best solution for the manufacture of affordable, high temperature capable composite tooling. ACG’s LTF318B surfacing film, used in conjunction with LTM®217 tooling prepreg, employs ZPREG selective impregnation technology to achieve a high quality surface finish on composite mould tools manufactured via low pressure, vacuum bag processing.
For cosmetic applications requiring a UV stable, superior visual quality surface finish, GTA Motor selected ACG’s OoA LTM®24ST, a controlled rheology resin matrix which is used for the surfacing ply of components moulded from LTM®26EL prepreg. LTM®24ST surface ply is partially impregnated to give asymmetric tack, and promotes a flaw-free, smooth surface and a low void content laminate under oven/vacuum bag moulding conditions, providing the exquisite, ultraviolet stable finish required for a car of this class. GTA Motor cured their cosmetic trim components via oven/vacuum bag processing, but LTM®26EL can also be processed in an autoclave or by press moulding.
Hugo Sosa, Designer and Head of Composites at GTA, said: “We selected ACG over other composite materials manufacturers for their excellent reputation in the motorsport sector, the wide range of materials (resins and reinforcement) available to us, and the fact that these could be fully tailored for a specific application. ACG also provided outstanding technical customer support at the start of our Spano program.” Please see the GTA website (www.gtamotor.com) for more information about the Spano super sports car.
Carlos J. Simarro, ACG Sales Manager for Spain and Portugal, said: GTA’s Spano is an amazing supercar; it is a unique combination of advanced technology and an incredible sporting spirit which is very difficult to match. The automotive market is just one of the sectors where we have experienced considerable success, and ACG is proud to apply its own tooling and components technology to help GTA Motor achieve its dream.
Images: Courtesy and © GTA Motor (www.gtamotor.com).
Upper image: The Spano’s unique styling.
Lower image: Internal cosmetic panel.
– Ends –
For further information, please contact:
Advanced Composites Group Ltd.
Dr. Jon Stowell – Sales and Marketing Director
E-mail: jstowell @ acg.co.uk
Carlos Simarro – ACG Sales Manager for Spain and Portugal
E-mail: csimarro @ acg.co.uk
Telephone: +44 (0)1773 766200
ACG’s Expertise and Advanced Prepregs used for Tooling and Body Panel Applications on an Exciting Automotive Project - 9th November 2011
Advanced Composites Group Ltd. (ACG) – part of Umeco Composites Structural Materials – a division of Umeco plc, is engaged in an exciting automotive project, part funded by the UK Technology Strategy Board (TSB), with collaborating partners UK-based Revolve Technologies Ltd. and IE-LEV Ltd. to develop and manufacture tooling and parts for a lightweight, range-extended electric-hybrid commercial fleet demonstrator vehicle.
This is possibly the first application of a lightweight composite intensive body in the light commercial vehicle sector. Reducing the weight of the vehicle is fundamental to optimising the performance and range capability of the electric drive train whilst maintaining a competitive payload.
Advanced Composites Engineering (ACE), ACG’s engineering division, has worked closely with the project team to develop the tooling and, using the company’s BPS240 body panel system, is now manufacturing the body panels for the demonstrator vehicles.
ACG’s BPS240 is a two-ply, partially impregnated epoxy prepreg system designed for the manufacture of Body-In-White (BIW) panels with excellent surface quality from vacuum-only processing at cure temperatures between 85 to 150°C. BPS240 is designed to be ready for painting without abrading or reworking. In many instances, paint can be applied directly to a degreased panel. However, in this application, the demonstrator vehicle panels will not be painted, but will use a vinyl wrap system already widely applied to commercial vehicles.
The aim of this collaborative project is to prove that the technologies used are suitable for application and use in a vehicle in this sector of the mass market. ACG was called upon to apply its expertise in composites manufacturing to minimise the weight of the body components, thus minimising the fuel used and carbon dioxide emissions. The concept will offer a whole new capability in the delivery van sector and present fleet operators with a cost-effective solution to the problem of achieving low carbon dioxide emissions without increasing running costs.
The project is currently in its ‘technology demonstrator’ phase with IE-LEV Ltd as the lead partner and Revolve Technologies as the main collaborating partner. IE-LEV has formed a subsidiary company ‘Emerald Automotive’ to take the project forward into its production phase. Based in St. Louis, Missouri, USA, Emerald Automotive will manufacture the vans, code-named t-001, for sale to large fleet operators in the USA and Europe.
Overall, and with the application of ACG’s prepregs, the t-001 will offer fleet operators an 80% reduction in emissions compared with conventional vehicles in the same class. Extensive research with fleet customers over the past three years has optimised the vehicle design and it is planned that, with a 463 mile range, the t-001 will give the first 66 miles at zero emission in EV (electric vehicle) mode. The t-001 will significantly reduce fuel costs and give fleet operators a lower lifetime cost per mile.
Bob Mustard, Technical Specialist from the IE-LEV Team, said: “ACG is a key development partner in our demonstrator vehicle programme. The engineering and commercial support has been critical to assist us in delivering proof of concept and in developing a viable route to production for a composite intensive body.”
Liam Moloney, ACE Engineering Manager, said: “We were delighted by the prospect of working with Revolve Technologies Ltd and IE-LEV Ltd., and to have the opportunity to assist in the development of their t-001 demonstrator vehicles. The project has progressed very well; ACE's manufacturing flexibility coupled with ACG's versatile BPS240 body panel prepregs have delivered everything that the customer required. BPS240 is already widely used in the automotive industry and has shown its ability in this distinctive demonstrator application, where low component weight and high panel stiffness were key requirements. ACG has the automation and materials technology that would assist Emerald Automotive in entering the high volumes manufacturing phase that they are anticipating. Additionally, our engineering facility has been fully involved in the design and the manufacture of the tooling, followed by production of the major external body panels required for this project. We wish Emerald Automotive every success as they move forward into the production phase.”
Image: © 2011 Emerald Automotive LLC. All rights reserved.
Note: The Technology Strategy Board is an executive body established by the Government to drive innovation. It promotes and invests in research, development and the exploitation of science, technology and new ideas for the benefit of business - increasing sustainable economic growth in the UK and improving quality of life.
For more information, please visit:
– Ends –
For further information, please contact:
Advanced Composites Group Ltd.:
Jon Stowell – Sales and Marketing Director
Telephone: +44 (0)1773 766200,
E-mail: jstowell @ acg.co.uk
New Delta Motorsport E-4 Coupé Takes Centre Stage on the Umeco Composites Stand at JEC 2011 - 18th March 2011
Advanced Composites Group, JD Lincoln, GRPMS, Richmond Aerovac and IPM will be co-exhibiting under the Umeco Composites banner on Stand No.: T50 in Hall 1 at the JEC Composites exhibition on the 29th, 30th and 31st March 2011.
Umeco Composites, a division of Umeco plc, operates as two business streams, namely Umeco Composites Structural Materials (UCSM) and Umeco Composites Process Materials (UCPM):
- Umeco Composites Structural Materials (UCSM) businesses Advanced Composites Group (ACG), JD Lincoln and GRPMS provide a range of complementary products, services, design expertise and tooling solutions to the composites industry.
- Umeco Composites Process Materials (UCPM) businesses Richmond Aerovac, IPM and Med-Lab serve global industries by supplying a range of vacuum processing materials and protective films, consumable short shelf-life hazardous aviation goods, and electronic equipment for testing fuels and heavy oils.
Each Umeco Composites business will display a range of exhibits, and personnel will be on hand to discuss individual product portfolios and technologies. The main exhibit on the stand will be Delta Motorsport’s E-4 Coupé, a vehicle which has been manufactured using ACG’s advanced automotive prepreg products.
Officially launched on March 7th at the European Automotive Industry Technology Roadshow, the E-4 Coupé is an all-electric road vehicle built using ACG’s innovative DForm® Deformable Composite System (DCS) for structures, next generation Body Panel System (BPS), and tooling prepreg materials. Delta worked with ACG on the carbon fibre integrated chassis and bodywork construction to generate a class-leading, low-mass vehicle together with a clear road map towards effective medium-volume production. The four-seater road car has been developed using a combination of ACG’s DForm DCS and next generation BPS, and has been engineered with a high level of parts integration in order to achieve maximum weight reduction compared with traditional materials. The Body in White (BIW) is manufactured from just fifteen bonded major composite panels and weighs only 85Kg, including the front and rear aluminium sub-frames, and crash structures.
Closures have been manufactured using carbon DForm for the internal panels and either glass or carbon BPS for the outer skins. This approach dispensed with the need to attach additional trim covers, which would have added weight to the vehicle and reduced that all-important mileage range.
The car also used a range of ACG’s prepregs systems for aesthetically pleasing seats. These prepregs use a range of high performance resins combined with woven, stitched and unidirectional fibre formats. With assistance from its carbon fibre fabric weavers, ACG has developed a Special Visual Quality (SVQ) material specification that maximises the aesthetic impact of carbon fibre finishes, ensuring that its products meet the exacting requirements set by the automotive interiors industry.
ACG’s in-house moulding facility and KS Composites, Delta’s moulding partner, manufactured the prototype parts using ACG’s single-sided DForm tooling, a product which is custom-formatted to produce the optimum, paint-ready surface finish direct from the mould. DForm composite tooling offers a number of advantages over standard long fibre woven fabric prepreg, and random short fibre and infusion tooling systems, and can offer savings of up to 30% in lay-up time. Its unidirectional fibre structure maintains dimensional accuracy and performance predictability. DForm creates an extremely flat, print-through-free surface profile with no local thinning, no loss of fibre orientation or variation in resin content.
Building on the success of its BPS240 Body Panel System, which is widely used by supercar constructors, ACG will be exhibiting an example of its new MkII BPS in the form of a boot lid. Targeted squarely at the medium to high volume market, where press mould processing is paramount, the innovative format further utilises DForm technology. ACG’s believes that this will play a major part in the development of rapid composites processing technology.
ACG’s MkII body panel system de-skills and reduces laminating time, and facilitates the production of flat surface profiles with minimal print-through, thus minimising surface preparation and reducing costs at all stages of manufacturing.
An award winning, innovative tooling solution, jointly developed by ACG and Integran Technologies Inc., will be on display in the JEC Innovations area. ACG and Integran won the JEC 2011 Composite Innovation Award - Equipment Category for Carbovar - Nanovate -NV surface composite tooling. The innovation combines the hardness, durability and damage tolerance of the nanometal coating with the lightweight, low thermal mass of a carbon fibre composite mould tool to deliver a durable and cost effective solution. The Nanovate surface is an ultra-hard, nanocrystalline nickel/iron alloy coating that has a low coefficient of thermal expansion (CTE) matching the CTE of the composite mould tool. The ultra-hard surface increases the longevity of the mould, becoming comparable to that of a conventional metallic mould tool. Composite tooling saves the energy required for the heat-up and cool-down phases, and the energy required to lift, rotate and manoeuvre them within the working environment, and during the lay-up process (faster material deposition rates).
Images: Delta E-4 Coupé - courtesy and ©Delta Motorsport Ltd.; Boot lid - ©ACG Ltd.; Tooling ©ACG Ltd 2011 - Carbovar - Nanovate - NV Surface Composite Tooling (editors - click here for access to images)
ACG’s representatives will be on hand to discuss and demonstrate the range of structural and body panel prepreg systems, together with prepregs which produce high quality aesthetic finishes, and associated tooling solutions.
For further information, please contact:
Advanced Composites Group Ltd.:
Jon Stowell – Sales and Marketing Director
Telephone: +44 (0)1773 766200,
E-mail: jstowell @ acg.co.uk
Advanced Composites Group Inc.:
Ed Mahoney – National Sales Manager
Telephone: +1 918 252 3922,
E-mail: emahoney @ acg-us.com
Aerovac Systems Ltd.:
James Bonnett – Business Development Manager
Telephone: +44 (0)1274 550532,
E-mail: jamesbonnett @ aerovac.com
Aerovac Systems France:
Didier Gal – General Manager
Telephone: +33 561 378987,
E-mail: d.gal @ aerovac.fr
GRPMS:
Tony Bibby – Managing Director
Telephone: +44 (0)1329 225201,
E
-mail: tony.bibby @ grpms.com
IPM:
Dario Canale – Managing Director
Telephone: +39 0174 552 551,
E-mail: dario.canale @ ipm-umeco.com
JD Lincoln:
Clint Refsnyder - Vice President - Sales & Marketing
Telephone: +1 949 650 8106,
E-mail: c.refsnyder @ jdlincoln.com
Additional Notes to Editors
Advanced Composites Group (ACG) (part of Umeco Composites Structural Materials [UCSM]) - manufacturer of advanced composites materials and tooling. ACG specialises in the manufacture of high performance composite materials for a diverse range of industries such as motorsport, aerospace, marine, automotive, construction, wind energy and leisure sports. The main focus of the Group's business, which operates through three divisions, is the manufacture of prepregs for components and tooling. ACG has manufacturing operations in Heanor and Manchester in the UK, and Tulsa in the USA. The Group is managed from its head office in Heanor and employs approximately 400 professionals worldwide.
JD Lincoln (part of Umeco Composites Structural Materials [UCSM]) - speciality materials and technology company that manufactures high performance adhesives and composite materials for aerospace, marine, medical, sporting, automotive and other extreme environment applications. JD Lincoln's products are technologically advanced including those designed specifically for aircraft interior applications. They are complementary to the other activities of Umeco Composites. Offices are located in Costa Mesa, CA and Adelanto, CA where we produced materials for over 350 customers worldwide.
GRPMS (part of Umeco Composites Structural Materials [UCSM]) - specialises in the distribution of GRP materials to the reinforced plastics market. GRPMS sets the standard in its field by putting customers in touch with a wide range of quality products. GRPMS is committed to providing premium quality products and an efficient service, delivering the right products at the right price, on time . . . every time. This extensive product range can now be accessed through the GRPMS web shop at www.tools4grp.com.
Richmond Aerovac (part of Umeco Composites Process Materials [UCPM]) - has subsidiaries located in Europe and the US, is a world-leading supplier of vacuum bagging consumables and associated products to the composite industry. Richmond Aerovac has a unique understanding of the dynamic requirements of the industry, supplying vacuum bagging products principally for the defence, aerospace, wind energy, marine, motorsport and industrial sectors.
IPM (Industria Plastica Monregalese Spa) (part of Umeco Composites Process Materials [UCPM]) - based in Mondovi, CN in Northern Italy, IPM is one of the world's leading companies in the co-extrusion and transformation of multilayered plastic films. The company has the capability and technology to manufacture extruded and co-extruded plastic films up to 18 layers thick using both blown and cast techniques. IPM offers a range of products designed specifically to meet customer requirements. Its products are sold into a number of sectors, ranging from industrial applications such as the advanced composites and automotive industries through to specialist medical and other barrier protective films for vacuum packing solutions.
Delta Motorsport Unveils its All-Electric E-4 Coupé with Advanced Composites Group at the European Automotive Technology Roadshow
Advanced Composites Group Ltd. (ACG), part of Umeco Composites Structural Materials (UCSM) - a Division of Umeco plc, will host Delta Motorsport Ltd. as it unveils its all-electric E-4 Coupé to personnel at Bentley Motors Ltd., Crewe, Cheshire, the first venue in the UK stage of the high profile European Automotive Industry Technology Roadshow (EAIT), which starts today (March 7th).
Attendees at all venues of the UK stage of the Roadshow will be able to view the E-4 Coupe and its innovative construction, which exploits ACG’s DForm® Deformable Composite System (DCS) in the chassis and also in the next generation composite Body Panel System (BPS).
Delta’s E-4 Coupé will also be the feature exhibit on the Umeco Composites’ stand (T50) at the JEC Composites show between the 29th and 31st March 2011.
Following the week-long UK stage the Roadshow will, throughout March, travel across Europe to Italy and Germany, where ACG will be exhibiting the composites technologies featured on the E-4 Coupé.
Delta worked with ACG to develop materials and process methodology for the carbon fibre integrated chassis and bodywork construction, generating a class-leading, low-mass vehicle with a construction philosophy that will carry it from prototype to medium volume production.
The four seater road car has been engineered with a high level of parts integration to maximise weight reduction. The Body in White (BIW) is manufactured from just fifteen major composite panels and weighs only 85Kg, which includes the front and rear aluminium sub-frames, and crash structures.
Closures have also been manufactured using carbon DForm for the internal panels and either glass or carbon BPS for the outer shell. This approach, dispensing with additional trim covers, further reduces weight and maximises the all-important mileage range.
The car also used a range of ACG’s prepregs systems for the aesthetically pleasing seats. In collaboration with its carbon fibre fabric weavers, ACG has developed a Special Visual Quality (SVQ) material specification that maximises the aesthetic impact of carbon fibre finishes, ensuring that its products meet the exacting requirements set by the automotive interiors industry.
ACG’s representatives will be on hand throughout the EAIT Roadshow to discuss and demonstrate the range of structural and body panel prepreg systems, together with prepregs which produce high quality aesthetic finishes, and associated tooling solutions.
Images: Copyright Delta Motorsport Ltd.
Read the ACG-Delta Motorsport brochure.
Read the ACG Automotive brochure.
– Ends –
For further information, please contact:
Advanced Composites Group Ltd.
Steve Cope (e-mail: scope @ acg.co.uk)
or
Mike Millward (e-mail: mmillward @ acg.co.uk)
Telephone: +44 (0)1773 766200
or
Delta Motorsport Ltd.
Simon Dowson (e-mail: simon @ delta-motorsport.com
Telephone: +44 (0)1327 858200
Additional Notes to Editors:
Delta Motorsport Ltd. is a design and engineering consultancy operating in motorsport and niche sectors of the automotive industry. From a vision and concept developed in late 2006, detailed work on the E4-Coupé commenced in December 2008. The company carries out concept studies together with detailed design and styling programmes. Prototype construction and low volume vehicle builds are also within the company’s scope. Delta specialises in working with novel vehicle architectures requiring a broad holistic understanding of all the factors which influence the solution – as with the E4-Coupé.
21st February 2011
Advanced Composites Group Exhibits Innovative Carbon Fibre Technologies on European Automotive Industry Technology (EAIT) Roadshow
Advanced Composites Group Ltd. (ACG), part of Umeco Composites Structural Materials (UCSM) - a Division of Umeco plc., will, as part of the Dream Marketing European Automotive Industry roadshow (EAIT), be visiting key Tier 1 and OEM automotive suppliers in UK and Europe throughout March 2011. The Roadshow will be visiting major automotive manufacturers, such as Audi, BMW, Bentley, Ford, Honda, Mercedes, Nissan and Toyota, giving their engineers direct access to ACG’s recent developments. Key ACG staff members will be on hand to discuss on-going and future potential interest in composite materials.
Composite materials, proven in motorsport and low volume supercars, are now exciting the mainstream automotive industry and the EAIT road show will be an opportunity for engineers engaged in the development of next generation road vehicles to see and discuss ACG’s most recent developments.
ACG will be featuring the DForm® Deformable Composite System (DCS) and its latest developments in composite body panel technology, both geared to higher production volumes while still maintaining the key performance benefits composites offer.
Visitors to the UK stage of the roadshow, which runs for the week commencing March 7th, will also see the launch of a ground breaking electrical vehicle which features many of ACG’s recent developments in its composite construction.
This vehicle will be a centre stage exhibit on the Umeco Composites’ stand at the forthcoming JEC Composites Show, Porte De Versailles, Paris, which runs from the 28th to 31st March. More information about this new vehicle will be revealed soon.
For up to the minute information on the EAIT Roadshow, please contact ACG or Dream Marketing.
– Ends –
For further information, please contact:
Advanced Composites Group Ltd.
Steve Cope (e-mail: scope @ acg.co.uk)
or
Mike Millward (e-mail: mmillward @ acg.co.uk)
Telephone: +44 (0)1773 766200
or
Delta Motorsport Ltd.
Simon Dowson (e-mail: simon @ delta-motorsport.com
Telephone: +44 (0)1327 858200
Additional Notes to Editors:
Delta Motorsport Ltd. is a design and engineering consultancy operating in motorsport and niche sectors of the automotive industry. From a vision and concept developed in late 2006, detailed work on the E4-Coupé commenced in December 2008. The company carries out concept studies together with detailed design and styling programmes. Prototype construction and low volume vehicle builds are also within the company’s scope. Delta specialises in working with novel vehicle architectures requiring a broad holistic understanding of all the factors which influence the solution – as with the E4-Coupé.
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