Faurecia Interior SystemsLess is More

Brett SchnurInnovation Project Leader

AGENDA

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CCB: Cross Car Beam

NAFILean Natural Fiber for Lean Design

Injection

Lignolite+ & NFPP+

Cross Car Beam

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COMMON WEIGHT & PERCENT OF VEHICLE INTERIORRepresenting 33% of the instrument panel weight, the CCB is the heaviest component.

CROSS CAR BEAM - The Key Figures

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Faurecia is approaching the cross-beam challenge from three directions that are driven by a “Less is More” perspective.

CROSS CAR BEAM - Innovation

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CROSS CAR BEAM - Faurecia’s Plug & Play

The Plug & Play Steel CBB offers a 5% reduction in weight.

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ABOUT THE PLUG & PLAY Variable thickness (from 1 to 2 mm) Variable diameter (from Ø40 to Ø80)

Variable Inertia

CROSS CAR BEAM - Faurecia’s Plug & Play

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CROSS CAR BEAM - Faurecia’s Hybrid CCB

The Hybrid CCB offers weight savings of up to 20%.

Sheet Molding Compound (SMC)

Steel from Plug & Play Technology

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The Composite CCB leads to weight savings of more than 40%.

CROSS CAR BEAM - Faurecia’s Composite CCB

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WEIGHT SAVINGS

CROSS CAR BEAM - Summary

Full steel CCB assembly using Cold Metal Transfer Welding

PLUG & PLAY CCB

HYBRID CCB

COMPOSITE CCB

Combines 3D SMC attachment brackets to Plug & Play steel technologies

Combines multiple technologies for maximum weight savings

Up to -5%

Up to -20%

Minimum -40%

2015

2016

2018

NAFILean

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AUTOMOTIVE PERFORMANCE MATERIALS

Natural fiber specialist headquartered in France Automotive injection

molding expert

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ABOUT NAFILEAN Polypropylene +20% natural fiber compound to

substitute for PE-MD20 and ABS Injection molding of covered DP trim parts, IP top

cover, defrost and closure ducts

COMPETITIVE ADVANTAGES Lightweight concept: up to -25% for door panel and -

20% for instrument panel, depending on architecture Green material with better environmental impact /

CO2 balance: -20 to -25% Life Cycle Assessment

NAFILean

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Natural Fibers for Lean Design Injection

DEVELOPMENT OF FAURECIA’S PP + NATURAL FIBERS COMPOUND

In production on Peugeot 308 door panel

Validated at multiple OEMs

One patent

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DOOR PANEL

NAFILean - Validated Parts

WEIGHT SAVED

25%

2-2.5mm thickTOP ROLLS

INSTRUMENT PANEL

BOLSTER / INSERT WEIGHT SAVED2-2.5mm thick

25%

DOOR PANEL CARRIERS2-2.5mm thick

WEIGHT SAVED12.5%Direct drop in

TOP PAD2-3.5mm thick

WEIGHT SAVED 20%

Density & thickness

DUCTS2mm thick

WEIGHT SAVED 20-25%

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PROCESS Injection Back injection Weakening by laser (air bag

function) TPO Thermo-covering Foam in place Vibration and U.S. Welding Fastening

Adheres to Design Standards

PRODUCT VALIDATION Dimensional behavior on instrument panel Sun load 120°C for 500hrs Climatic aging Air bag deployment Head impact NVH – CAE Comparison Foaming Side impact Repeated load durability

Often Better Than Production

NAFILean - Interior Validation

Compression-Molded Mat Technologies

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NATURAL FIBER MAT

TWO TYPES OF IMPROVED LIGHTWEIGHT COMPRESSION-MOLDED MATERIALS

LignoLite+ NFPP+ (Natural Fiber

Polypropylene)

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ABOUT LIGNOLITE+ Lightweight door panel carriers made from

Wood Fiber Composites (WFC)

Based on hot press technology

Made up of 85% natural fibers, bio-based material, green and renewable material

Contributes to weight reduction—up to 25% savings vs. currently used lightweight solutions

Up to 45% savings vs. injected carriers, resulting in CO2 reduction and integration of renewable materials

LIGNOLITE+ Door Panel Application

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Resin 1 Resin 2 Resin 3 Wood FibersBonding Fiber 1 Bonding Fiber 2 Other Fibers Wax

Lignotock

Lignotock+

Lignoflex ECO

Lignoprop

LignoLite

LignoLite+

Resin 3 Wood fibers Other fibers

LIGNOLITE+ Tailored to Your Application

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NFPP+ Door Panel Application

Common industrial mat weight =

1450 gsm

1250gsm mat available

Weight savings of 14% (vs. common

mat)

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CCB:Cross Car Beam

NAFILean Natural Fiber for Lean Design

Injection

Lignolite+ & NFPP+

Validated to Multiple OEM Specs Weight Savings : DP = Up to 25%

IP = Up to 20%

Weight Savings of 45% vs. Standard Injection Materials

Weight Savings : up to 40%

CONCLUSION