sustainable growth opportunities of carbon fiber
TRANSCRIPT
© Copyright STRUCTeam Ltd
Sustainable Growth
Opportunit ies of Carbon Fiber
in the Automotive Sector
Dr.-Ing. Roman Hillermeier
Competence in Automotive-Composites Engineering
& Development Services
2025
2020
2015
2010
Date: 5/12/2021 © Copyright STRUCTeam Ltd Slide: 2
S T R U C Te a m Lt d . I n t ro d u c t i o n
Renewable / Wind Energy
Marine
Material
Supply Chain
Manufacturing
Design
Engineering
Leading composites engineering services consultancyOil & Gas
Materials Industry
Automotive
Civil STL Formation
Pullwind
serv
ing
mu
ltip
le s
ect
ors
> 3
0 %
re
ven
ue
> 3
0 %
re
ven
ue
Wind
Energy
Transportation
~ 80% of revenue base
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A ge n d a
History and Market of Automotive Carbon Fiber based Composite Applications
Trends & Drivers
Automotive Segments
CFRP Growth Areas
Date: 5/12/2021 © Copyright STRUCTeam Ltd Slide: 4
A u t o m o t i ve C o m p o s i t e s H i s t o r y
1953 Corvette C1. GFRP body
1957 Trabant, cotton reinforced phenolic exterior panels
Lotus Elite, GFRP monocoque
1960s SMC is invented
1972 All body panels of Corvette use SMC
1981 GM Corvette GFRP leafspring
First F1 monocoque in CFRP
2011 BMW I3 CFRP lifecell
Lamborghini Aventador CFRP monocoque
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2 0 1 5 B M W 7 – I n d u s t r i a l i ze d C F R P P ro d u c t i o n
Focused CFRP deployment - Buildrate technologies > 50000/yr
Source:
CompositesWorld
A u t o m o t i ve C a r b o n F i b e r M a r ke t
0.000
5.000
10.000
15.000
20.000
2020 2026
Carbon Fiber (MT) in Auto Applications
2010 2015
Automotive % of Total Market for Carbon Fiber
Serial Production
Racing Cars, Sports
Cars, After Market,
Brake Discs, Wheels,
etc.
~5% ~8% ~9% ~10%
Source: CarbConsult
un
cert
ain
ty
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M a r ke t S h a re fo r Pa s s e n ge r & C o m m e rc i a l Ve h i c l e s
b y Po w e r t ra i n Te c h n o l o g y
• @ 2kg CFRP / EV&FCEV in 2030 = 60kt market potential
• @ 4kg CFRP / EV&FCEV in 2040 = 300kt market potential
DISRUPTIVE MARKET
ENVIRONMENT
Opportunities
for
NEW
STRUCTURAL
LIGHT-WEIGHT
Materials
I) Powertrain Shift
II) Autonomous Driving
III) New Ownership
Models
IV) Trend I)-III) accelerate
product commoditization
NEV: BEV, FCEV Higher weight vs. ICEs
Increased safety requirements
More users / mileageHigher durability
Fast technology introductions
become key product differentiators
I m p a c t o f G l o b a l M a r ke t Tre n d s
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Te c h n o l o g y I m p a c t o n E V A rc h i t e c t u re
Factor Structural Needs Functional
Integration
High vehicle weights ++ +
Package space / height impact by energy storage systems ++ ++
4wd & extreme acceleration + +
New risks from energy storage systems ++ ++
Growing sustainability importance – to + – to +
Clean sheet designs & green field production opportunities + +
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Ve h i c l e S e g m e n t O p p o r t u n i t i e s
Vehicle Segment Applications Growth
Commercial vehiclesBus
Trucks
LCV – HCV
• Energy storage / powertrain
• Exterior
• Chassis
Strong incremental - select
opportunistic
PremiumSUV
Full-size
Mid-size
• Energy storage
• Structural – semi structuralExponential
Compact
• Energy storage Incremental
Super premiumSuper car
Luxury vehicles
…
• Structural
• Energy storage
• Exterior / Interior
• Chassis
Strong incremental
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F u e l C e l l E l e c t r i c Ve h i c l e s
FUEL CELL
Electrode materials (anodes and cathodes)
=> Carbon fiber paper preferred solution
H2 STORAGE SYSTEMS
Type 4 composites tanks, 350-850 bar
GROWTH ENABLERS
• Competing “GFRP <-> CFRP” designs • Suitable CF supply chain & product portfolio
• Maximizing fiber utilization thru improved
technologies
Source: www.fuelcellstore.com
Source: Faurecia
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E l e c t r i c Ve h i c l e B a tt e r y E n c l o s u re s( f o r B E V, F C E V, H E V )
Battery enclosures are complex structures which need to fulfill many requirements. Evolving vehicle architectures make advanced
composites an attractive material choice for the enclosures of future EVs.
COMPOSITE BENEFITS
+ Unsurpassed strength-to-weight ratio
+ Fire protection and insulation
+ Part integration capability
+ Buildrate flexible manufacturing technologies
+ Weight & cost
CHALLENGES
- Complexity in design & development
- Dispersed supply chain
- Integration into EV architecture
DEVELOPMENT NEEDS
❖ Improved structural & functional integration
❖ Stronger participation as structural member
❖ Simpler thermal management solutions
Source: Audi
Source: Tesla Battery Day
Source: Carmagazine
C F R P i n E V E n c l o s u re s
• Heat shielding
• Li-Fire protection
• EMI shielding
• Electrical insulation
• Thermal management - cooling
• Road impact
• Drive-obstacle impact (SUV)
• Maintenance abuse intrusion
• Thermal insulation
• Road-side fire protection
• Side, rear, front crash
• Water ingression
Load Spectrum from
• Battery weight
• Driving operation / BiW interaction
• Crash events
• …
Complex requirement profile
Vehicle & OEM specific objectives
Weight & space constraints
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CFRP Enablers
High specific strength & stiffness capabilities
Multi material designs => use CFRP where it brings most value
Maximize component loading potential in design process
CFRP Inhibitors
Cost & supply
Sustainability aspects
Inefficient development process
M u l t i M a t e r i a l C o m p o s i t e E n c l o s u re s
- I n d u s t r y P ro g re s s -
Commercial
Feasibility
Concept Design
Detail Design
Prototype
Preproduction
Serial Production
TRL 1 - 3
TRL 9
TRL 7 - 8
TRL 5 - 6
TRL 4
Current Status
2023 – 2025 Date: 5/12/2021 © Copyright STRUCTeam Ltd Slide: 14
S T L’ E n c l o s u re D e ve l o p m e n t P ro c e s s
Development of light and cost competitive battery boxes & delivery into vehicle platforms
Fea
sib
ilit
y S
tud
y &
Bu
sin
ess
Ca
seO
EM
ne
w P
latfo
rm In
teg
ratio
n
Composites Battery Box Development
Design
Concept
Material
DefinitionPart Validation
Manufacturing
Process
Integration into existing Technology Platform
PHASE 1 PHASE 2 PHASE 3
2-3 months 6-9 months 6–24 months
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C o n c l u s i o n s
Composites have achieved a good level of technical maturity
Sustainable growth opportunities for advanced composite materials with paradigm
shift to NEV powertrains
Growth potential for CFRPs are substantial in selected applications, but supply and
cost inhibit broad use in automotive
Needed innovation speed, require strong collaboration with development partners
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C o n t a c t
Dr.-Ing. Roman Hillermeier
(Head of Transportation Business Sector)
E-mail: [email protected], T: +49 (0) 163 1665164
STRUCTeam Limited
Old Riggers Loft
Marina Walk,
Cowes, Isle of Wight
PO31 7XJ, UK
www.structeam-ltd.com
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