global automotive lightweight materials brochure

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OEM BEST PRACTICE CASE STUDIES: In-Depth Focus Benchmarking Progress Of Single And Multi-Material Solutions For Cost Effective Lightweighting

BODY-IN-WHITE WEIGHT SAVINGS: Scrutinising Approaches To Balancing Weight Gains From The Body Structure With The Impact On Performance

MATERIALS SUPPLY: Aluminium, Magnesium, Carbon & Alternative Composite Suppliers’ Views On Enabling Widespread Adoption And Steps To Forging A Harmonised Global Supply Chain

SCALABILITY: Introducing Strategic Visions And Technical Solutions For Scaling Up And Implementing High Volume Multi-Material Lightweight Solutions

FORMING, TOOLING & JOINING: Comprehensive Per Material Analysis On Carbon Fibre, Aluminium And Hybrid Materials Analysis To Systematically Improve Forming, Tooling And Joining Techniques For Lightweight Vehicles

AUTOMATION: Extensive Per Material Analysis Of Meeting The Remaining Challenges Of Automating Parts Processing For Sufficient Volume And Mass Market Scalability

TECHNOLOGICAL INNOVATION: Identifying Solutions, Cultivating Collaboration and Capitalising On R&D breakthroughs To Support Reduced Cost Of Manufacturing Lightweight Materials Without Compromising Performance

Examining Gram Strategies, Best Practice Experiences And Approaches To,

Tackle The Challenges Of Sourcing, Integrating & Manufacturing Light Weight Materials To Deliver Improved Fuel Economy Commercially Viable Routes For Mass Market Application

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Dr Markus Pfestorf Manager Material Concepts For Body-In-White Construction BMW

Expert Insights From World Leading Vehicle OEMS Including:

Christoph Haberling Environmental Product & Materials Technology Audi

Claudio Santoni Function Group Manager Body Structures McLaren Automotive

Mark White Chief Technical Specialist - Light Weight Vehicle Structures Jaguar Land Rover

Professor Frank Henning Lightweight Construction Fraunhofer Institute

Alex Markin Managing Director International Magnesium Group

Dr. Jiro Sadanobu General Manager Teijin

Daniel Jubera Director Sales & Marketing Novelis Europe

25-26 April, 2012Business Design Centre

LONDON | UK

Plus, Global Material Suppliers, Including:

To register: call 44 (0)20 7033 4970 email [email protected]

Dear Colleague,

Would you like to understand how to cost-effectively source, integrate and manufacture lightweight metallic and composite materials into vehicle systems?

If so, we invite you to join us at Global Automotive Lightweight Materials 2012 where BMW, Audi, McLaren, Jaguar Land Rover, TATA Motors, Bugatti, Fiat Auto, Ford and many more will provide you with best practice experiences and their approach to tackling the challenges of sourcing, integrating and manufacturing lightweight materials to deliver improved fuel economy.

Clearly lightweight materials will be a signi!cant factor in meeting increasingly stringent carbon emission regulations, providing customers with improved MPG fuel economy and boosting vehicle OEM gram strategies.

With joint ventures formed by BMW & SGL, Audi & Voith and Daimler & Toray, arguably the world leaders in vehicle lightweighting, it seems adoption of advanced metallic and composite materials is set to dramatically increase. Of course though, it is widely recognized that key challenges of both cost and performance must be tackled to achieve the levels of scalability required for mass market application.

Day One of Global Automotive Lightweight Materials 2012, through a comprehensive case study analysis, will benchmark current approaches and identify remaining barriers through a per material cost bene!t analysis managing the trade offs between cost, performance and weight before welcoming Material Suppliers to examine the central concern of enabling a harmonized global supply chain, supporting you in !nding pragmatic, cost-justi!ed solutions to achieving scalability.

Day two will showcase the latest developments from research & development institutions to aid stakeholder collaboration and following that, you will witness key vehicle OEMs analysing manufacturing infrastructure concerns, the labour intensive forming and tooling processes and joining of dissimilar materials before closing discussions with the crucial topic of examining how to decrease energy usage and minimise material wastage across the manufacturing cycle.

Designed by your industry peers, Global Automotive Lightweight Materials 2012 this idea generation platform will deliver the latest solutions for a technical and commercially viable lightweight strategy. Browse through the enclosed agenda and visit

www.global-automotive-lightweight-materials.com for the fastest way to register.

I look forward to meeting you in April.

Ben JeffreysConference Director, Automotive Innovation

Sponsorship And Exhibition Opportunities At Global Automotive Lightweight Materials 2012

Need to generate new sales leads, engage key decision makers, build new future business relationships in key markets, or simply educate the industry about a new product? Then you need to sponsor or exhibit at Global Automotive Lightweight Materials 2012. Our busy exhibit area is an integral part of the Summit and is of genuine practical value to delegates, who are looking for new solutions and technologies. Becoming a Conference Sponsor will help you position yourself as a market leader and centre of excellence to the key decision makers in the automotive industry.

For further information, email: info!london-business-conferences.co.uk or call: 44 (0)20 7033 4970

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• Benchmark your gram strategy and benefit from a 360° analysis of how OEMs are approaching lightweighting challenges to meet emissions targets and deliver improved fuel economy to the customer

• Hear directly from Material Suppliers on their approach to establishing a consolidated global supply chain, allowing a commercially acceptable source of advanced lightweight materials across the automotive industry

• Discover the most innovative Body-In-White weight reduction strategies: Assessing the trade-offs between weight, cost and performance for different multi-material solutions

• Share in comprehensive per material analysis to decipher how to achieve sufficient scalability of lightweight materials: Assessing realistic solutions to both technically and commercially enable automation

• Deliver reduced CO2 emissions across the vehicle life cycle: Examine how to make efficiencies and reduce wastage across composite material manufacture

• Engage in collaborative discussions and cultivate relationships across the supply chain including leading R&D institutions, OEMs and Material Suppliers

• Evaluate the latest technological innovations for joining, tooling and forming to assess how they can support your gram strategy allowing cost-effective high volume manufacturing of lightweight materials without compromising technical performance

25-26 April, 2012Business Design Centre

LONDON | UK

Register Before Friday 17th February 2O12to take advantage of the super early bird rate, saving you £2OOSee back page for booking details


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OPENING KEYNOTE PANEL: LIGHTWEIGHT MATERIALS GRAM STRATEGY

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Developing a commercially viable gram strategy for integrating lightweight materials – where are gains most likely to be made?Judging views on what materials strategies are realistically available for single material usage or a mixed-material usage - What level of expectation can be delivered from these strategies in the short, medium and long-term?Understanding the existing challenges, how these are being approached and where the most viable areas for commercial success lie Tackling the bottlenecks of material supply and high capital costs of material application – assessing the most viable routes to high volume productionMarrying the expertise of material developers with OEMs knowledge of material application to establish a realistic and mutually beneficial path to high volume productionAssessing the impact of future technological developments and strategically preparing for future light weight requirements to meet legislation demands and consumer needs for fuel economy!"#$%&'()*+!"#$%&!'%(#)$(*+!,-%($*+$./!0!1$2#/3%$2#/!,/45(/54%.6'()*+),'-)./'0123,,#-%!"#$./%01*/)2#1+!7*)*2%4!7*/%4$*+!"8)(%-/.!984!:8;<=>)=?#$/%!"8)./45(/$8)6'456

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OEM BEST PRACTICES: BENCHMARKING PROGRESS AND IDENTIFYING REMAINING

CHALLENGES THROUGH COST-PERFORMANCE ANALYSIS OF ALUMINIUM, MAGNESIUM, CARBON FIBRE AND ALTERNATIVE

COMPOSITES SOLUTIONS

CASE STUDY 1: LUXURY MARKET BODY-IN-WHITE & VEHICLE SYSTEM

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Introducing low volume manufacturer’s views on the lowest possible investment routes to complete the tooling processesExamining strategies for cheaper low cost press tooling to improve ROIEvaluating the current manufacturing practices of low volume manufacturers to provide guidelines for future high volume adoptionUsing the economic constraints of operating a small volume production process as a guide efficiency through high volume manufacture

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CASE STUDY 2: SINGLE MATERIAL COMPOSITE VIEW FOR BODY STRUCTURES

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Understanding composites material characteristics for accurate assessment of how they can be best utilised for what you want them to doEstimating how to increase the fibre volume fraction and the most optimal fibre alignment strategy to improve part performanceBenchmarking against steel to dictate the performance levels required by composite materialsHighlighting composite materials responses to crash situations to define the required energy absorption characteristics

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CASE STUDY 3: MIXED MATERIAL SOLUTIONS FOR BODY-IN-WHITE

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What mixed-material solutions have shown feasibility for cost effective light weighting of the body-in-white to deliver improved fuel economy to the customer?Evaluating high strength steel for structural components and carbon fibre for non-structural components to deliver promising crash impact resistance resultsHow can we enable accurate prediction of crash modelling and crash behaviour of composites to ensure structural performance?To what extent are current simulation models applicable to composites?Understanding the complex joining, tooling and corrosion demands of a multi-material body in white structuresIdentifying a solution to the issues of joining metallic to composites Examining thermal responses and impact on choice of composites Benchmarking progress towards mass market application and assessing pragmatic solutions to meet the remaining challenges enabling advantageous weight benefits within a commercially viable cost,#-%!"#$./%01*/)2#1+!7*)*2%4!7*/%4$*+!"8)(%-/.!984!:8;<=>)=?#$/%!"8)./45(/$8)6'456

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CASE STUDY 4: COST EFFECTIVE LIGHT-WEIGHTING OF THE UNDERBODY

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1$2+&%$3Proposing how to design the floor plan to accommodate advanced metallic and composite materials - Assessing software solutions to assist design optimizationEvaluating the performance vs cost of alternative lightweight materials to varying environmental conditions: potholes, weather and dirtHighlighting crash load responses and cost benchmarks from steel to indicate performance levels of lightweight materials

i. Metallic Materials ii. Composite Materials

Assessing areas where the most gain can be made to lightweight the floor plan – capitalising on new technologies

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CASE STUDY 5: STEEL AND ALUMINIUM FURTHER WEIGHT SAVINGS

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Highlighting recent advances in steel technology that could provide cost effective weight savings within existing framework – will this rival the weight aluminium body structures?Determining future technology developments as a catalyst for extracting further mass from the vehicle – what are the expected timeframes of introduction and costs associated with new and innovative technology?Examining the opportunities for a multi-material steel & aluminium body in white to display cost & weight resultsIntroducing software optimisation as a tool for extracting further weight from future steel body-in-white structures

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CASE STUDY SUMMARY

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Predicting how to accommodate the differing surface energy of metallic and composite materialsAnalysing the impact on joint performance of coefficient of thermal expansionExamining ‘hybrid’ joint techniques such as self pierce riveting and adhesives for improved joints between metallic and composite components

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MATERIAL SUPPLIERS’ VIEW ON FORGING A COMMERCIALLY VIABLE ROUTE TO MARKET FOR A CONSOLIDATED AND

HARMONISED SUPPLY PARTNERSHIP

MATERIAL SUPPLY PARTNERSHIPS

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Understanding the current fragmented nature of supply and considering pragmatic steps towards a commercially viable solutionDrawing on expertise from university and R&D knowledge centres to enhance interaction with the automotive industryReviewing and analysing two large EU projects to develop carbon fibre-based composite technologies for high-volume applicationDiscussing future strategies to guarantee efficient collaborations on composites for a cost-effective lightweight strategy

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Suppliers views on cost projections and capability for large series productionWhen realistically can each material be available in quantity?What is being done to secure supply?What is currently being done to eliminate the lack of materials and competing demands of the aerospace industry?How can key bottlenecks be pragmatically solved in a commercially viable way for all stakeholders?

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KEYNOTE PANEL: INCREASING STAKEHOLDER COLLABORATION

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Drawing on the contribution of research institutions to reduce OEM R&D risk and costLeveraging the ‘tried and tested’ from R&D institutions to guide future commercial strategy for integration of lightweight materials and realisation of a more fuel efficient vehicleExamining the opportunity for industry wide relationship building to meet supply and demand of predicted future material volumesIncreasing collaboration and synergy between vehicle OEM and service providers to distribute responsibility and cost for research into manufacturing methodsIdentifying new and improved sources in collaboration with government: Capitalising on transferable lessons from aerospace for the integration and application of composites

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MANUFACTURING INFRASTRUCTURE: EXPLORING THE FEASIBILITY OF LEVERAGING EXISTING

INFRASTRUCTURE AND IMPLEMENTING A COST EFFECTIVE APPROACH TO SETTING UP NEW PLANTS TO ENABLE VOLUME

PRODUCTION OF ADVANCED LIGHTWEIGHT MATERIALS

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Assessing manufacturing processing requirements of lightweight metallics and composite materials to outline the best strategies for infrastructure deploymentUncovering the global cost challenges of building new plants in a commercially viable timeframe and assessing specific topline challenges with:

i: Aluminium ii: Magnesium

Pragmatic considerations for setting up a new plant - forecasting the investment levels required to accommodate predicted high volume composite manufacturingAssessing what materials can realistically be integrated into the current steel infrastructure? Is it feasible to integrate build lines? Analysing the transferability of current manufacturing plants to streamline future adoption of forming, tooling & joining technologiesIntroducing new manufacturing technologies into existing plants to produce new component parts at increased rates

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MANUFACTURING PROCESSING: EVALUATING THE MANUFACTURABILITY AND ASSEMBLY

COSTS ASSOCIATED WITH ALUMINIUM, MAGNESIUM, CARBON FIBRE AND ALTERNATIVE COMPOSITES TO OFF

SET REMAINING CHALLENGES AND GENERATE A REALISTIC FUTURE STRATEGY FOR HIGH VOLUME PRODUCTION

AUTOMATION

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Summarising recent aluminium automation developments and cost estimates to predict the material’s future applicability as a mass market contender for body in white structuresEvaluating aluminium as the ‘short-term’ scalable lightweighting solution for body in white structures – how significant are the remaining barriers to mass market adoption and what is the vision for tackling these?Contemplating the scalability of aluminium to rival current high strength steel manufacturing times and cost per part

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8!#%!'U3??=1.'4V!Identifying previous automation of high-volume metallic manufacturing accomplishments to reveal successful part production scalingForecasting investment levels and payback period to develop automated processing for magnesiumKey avenues and areas of future technological development that could produce a commercially viable solution for widespread adoption of magnesium?

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What are the key bottlenecks preventing automation of carbon fibre parts processing? Can these be pragmatically be countered in a commercially viable timeframe?What type of technology would be necessary to allow the efficient processing of carbon fibre for high volume?How feasible are the cost projections to enable automation of manufacturing processes suitable for carbon fibre processing?Assessing realistic solutions to both technically enable automation, and strategically in terms of cost effectivenessHow could mass-market volume manufacturing impact on carbon fibre composite part quality?

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ASSESSING THE SPECIFIC BENEFITS AND LIMITATIONS EXPERIENCED IN THE FORMING, TOOLING & JOINING OF

DIFFERENT LIGHTWEIGHT MATERIALS TO DELIVER VOLUME PRODUCTION FOR ECONOMIES OF SCALE

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Identifying the feasibility of a stamp-forming process to deliver part quality and reduce time and cost per part manufacturing processesComparing self-pierce riveting and hot or cold curing adhesives to maximise join performanceExamining how to develop composite tooling materials that can facilitate complex composite parts efficiently and cost effectively

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Assessing how to utilise existing process and technologies to maximise forming, joining and tooling capabilities efficiencyEvaluating how to drive efficiencies of joint performance of welding, riveting and adhesive bonding whilst maintaining part qualityAnalysing optimum proportions of extrusions, castings and stampings for cost-effective body-in-white light weighting

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SOFTWARE – OPTIMISING THE DESIGN PROCESS

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Assessing the most effective CAD/CAE software packages for optimising the design process for compositesEvaluating software design processes to introduce specific steps for an holistically designed body structureEffectively utilising software packages to help predict the behaviours of composites – how reliable are current tools in their analysis and results?Investigating the remaining challenges with software packages maturity for alternative materials usage for body structures

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REDUCING OVERALL CO2 EMISSIONS BY DECREASING ENERGY USAGE & EVALUATING HOW TO COMPLY WITH THE END OF LIFE VEHICLE DIRECTIVE THROUGH MINIMISED MATERIAL

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CO2 OUTPUT AND END OF LIFE VEHICLE DIRECTIVE

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BIG PICTURE VISION: ENABLING COST EFFECTIVE SCALABILITY OF MULTI-MATERIAL

LIGHTWEIGHT SOLUTIONS

ACHIEVING SCALABILITY MANUFACTURING PANEL

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Evaluating how light weight composite and metallic materials can be integrated into a high volume applicationUnderstanding the necessary investments required to deliver an automated and highly efficient manufacturing processAnalysing how to decrease production time to improve cost per part ratiosAssessing strategies to indicate plant investments required to facilitate high volume production

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20% Heads of Lightweighting Strategy

16% Chief Engineers

12% Heads of Exterior

24% Senior Managers of Body Structures

10% Material Directors

18% Engineers (BIW, Design, Composites)

56789:!&+!6$!;8.<;!$=6+56&:;>?Advanced Lightweight Materials for the automotive sector is a growing area of technological development. You may be pioneering these advances, but do your customers know what differentiates you from your competitors? Use targeted, editorially reviewed keynotes and case studies to demonstrate thought leadership to your target audience.

&+>:6$@&+95$+A+&696::$+95$>9B&6+:6$C8.&$?&8D>=6Any solutions selected by Vehicle OEMs must be subjected to careful comparative cost-benefit analysis. Of course automakers take into account, profile, credibility and market leadership when selecting suppliers to support, their lightweighting strategies. Your organisation must be at the forefront when these decisions are made.Cement your leadership position with targeted branding and profiling campaigns directed at the leading Vehicle OEMs.

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Thought leadership, branding and profiling are converted into contracts through extensive face-to-face relationship building. As a dedicated event to Lightweight Materials, this intimate forum enables you to meet specific job titles in one place at one time, giving you the best possible chance of influencing key decision makers.

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55% Vehicle OEMs

15% Material Suppliers

25% Material Manufacturer Suppliers

5% R&D Institutions

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The Summit will be held at theBusiness Design Centre52 Upper Street London N1 0QH+44 (0)207 288 6272

www.businessdesigncentre.co.uk

Situated in fashionable Islington, the Business Design Centre is

London’s most stylish exhibition centre in the UK. Opened 20 years

ago in 1986, and formerly the Royal Agricultural Hall, the building

was rescued from demolition in 1981 by entrepreneur Sam Morris

and was fully restored and re-opened as the UK’s first integrated

trade, exhibition and conference complex.

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To secure your sponsorship or to discuss further, please contact Steve Thomas

on 44 (0)20 7033 4970 or email steve!london-business-conferences.co.uk


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