ENGEL Mobility Days

Hybrid components made of different materials that are joined together. The right material in the right place.
Use of sustainable materials and the recycling strategy at the end of life.

The presentation will include Volvo Cars sustainability ambitions and current status.
Trends and challenges regarding sustainable plastics in the automotive industry will also be discussed. 

"Megacasting" is one of the most widely discussed trends when it comes to the body-in-white.
With the production of ultra large structural castings in aluminum – so called “megacastings” –, the body-in-white of cars can be produced in a more sustainable and cost-effective way. Since one large part can now replace what used to be 70 parts, the complexity of assembly is reduced significantly.

This trend results from a steady development. The first German premium brands already started introducing structural aluminum die-cast components in the 90s. The production of ever larger parts consequently required die-casting machines with higher locking forces and bigger shot weights. One of these large solutions – the Carat 840 – will also be on display at the ENGEL site in St. Valentin.

Sustainability is anchored at the highest level at Volkswagen. Alongside climate protection, the Circular Economy is an important goal. Volkswagen is already very active in this area with the battery recycling pilot plant at the Salzgitter site, and further Circular Economy technologies are being developed in the research consortium of the Open Hybrid LabFactory. One focus here is on plastics recycling.

The presentation deals with established production methods in the aerospace industry and highlights the necessary transformation of the industry in terms of sustainable and high-rate material and process technologies for the production of lightweight components in the field of advanced air mobility.

Lightweight design approaches and the demand for sustainable and recycleable materials for mass production have been door openers for a multitude of new applications for organo sheets in the automotive industry. In this lecture, a new series application and the challenges on the project's way to mass production will be shown.

Hollow parts reveal the best torsional stiffness to weight ratio and are the choice for various applications in the mobility industry. In the presentation an engineering route map is presented to numerically design, produce and test thermoplastic bicycle frames. With this approach many challenges of future mobility are addressed and solution for mass produced structural components are demonstrated.

• Rollercoaster: New mobility as a chance
• The human touch: Impact of resource scarcity and changes in consumer behaviour
• No way out: Impact of sustainability demands + regulations
(ESG, supply chain protection law, run out of ICE technology)
• The world is not enough: Global, regional, local - where to go, and how?

Advanced Air Mobility will soon revolutionise our mobility and AutoFlight is playing a key role in driving this development. With an international team and an exciting technical concept, AutoFlight has the potential to become one of the top players in the AAM market.

Cellcentric – a joint venture of Daimler Truck AG and the Volvo Group AB formed in 2021 - develops, produces and commercializes fuel-cell systems for use in heavy-duty trucks and other applications. Its ambition is Cellcentric, will introduce into the fuel cell technology and leads through the company’s journey from the first prototypes to the planned mass production.

By looking to make the best skateboard on the market, we worked out a manufacturing method that solves the three main problems of the composite industry: costs, production time and recyclability.
"Cost-Efficient Thermoplastic Endless Fiber-Reinforced Composite Sandwich With A Molded Foam Core
Via In-Situ Polymerisation With Recycled E-Caprolactam (PA6)"

Industrialization of a thermoplast composite re-enforced front end module.
High Level of Component Integration into Injection Molding Process reducing energy consumption due to eliminated post-assembly process steps. One shot injection molding process. Pre-cut organo sheets are inserted and formed in the injection molding tool combined with multiple additional inserts which are handled overmolded together to a complex composite hybrid.

The sustainable impact of origami construction on R&D costs, the production cost  of vehicles, performance and safety and the related vehicle Co2 footprint.

• full thermoplastic battery housings with functional integration
• integrated thermoplastic features to enhance cooling performance for HV batteries
• lessons learned and industry insights from concept/design/manufacturing and validation of IM components in battery enclosure/thermal systems

ENGEL will be showing the latest technology on the subject of recyclate processing - technologies from recycling extrusion integrated into injection moulding. The special processes on show offer numerous - additional - advantages. The processing of long glass fibre reinforced materials will be dealt with in particular.

Presentation of the process tape reinforced injection moulding; improvement of the mechanical properties through tape reinforced injection moulding; analysis of the environmental impact --> reduction of the GWP through reduced material use; presentation of the component and the process.

The lecture focuses on the overarching theme of "The Coming Structural Change" - the megatrends driving the change are "digitalisation and sustainability".
The 20s and 30s will be the most dynamic decades in human history and many established companies and industries will undergo massive change.
In focus: How is the mobility industry changing?

Topics:
• Multi modality
• New City Concepts
• Sustainability – CO2 Emissions and Fleet management
• New hardware – from cars to planes

Demystifying the mobility labyrinth.
Dirty, decrepit, wet, and aged roads are the reality of cities. Our solo journeys through metropoles often mean navigating century old networks designed for a different age and battling with thousands of other vehicles.
This is a far cry from the perfectly organized gleaming white and sun-streaked electric utopia’s that we seem to think we are designing for.
How do we design for the NOW without ignoring our obligation to up our game?

Global market outlook
Market and competive trends (disruptive challenges)
Potential implications for automotive suppliers

Hybrid components made of different materials that are joined together. The right material in the right place.
Use of sustainable materials and the recycling strategy at the end of life.

The presentation will include Volvo Cars sustainability ambitions and current status.
Trends and challenges regarding sustainable plastics in the automotive industry will also be discussed. 

"Megacasting" is one of the most widely discussed trends when it comes to the body-in-white.
With the production of ultra large structural castings in aluminum – so called “megacastings” –, the body-in-white of cars can be produced in a more sustainable and cost-effective way. Since one large part can now replace what used to be 70 parts, the complexity of assembly is reduced significantly.

This trend results from a steady development. The first German premium brands already started introducing structural aluminum die-cast components in the 90s. The production of ever larger parts consequently required die-casting machines with higher locking forces and bigger shot weights. One of these large solutions – the Carat 840 – will also be on display at the ENGEL site in St. Valentin.

Sustainability is anchored at the highest level at Volkswagen. Alongside climate protection, the Circular Economy is an important goal. Volkswagen is already very active in this area with the battery recycling pilot plant at the Salzgitter site, and further Circular Economy technologies are being developed in the research consortium of the Open Hybrid LabFactory. One focus here is on plastics recycling.

The presentation deals with established production methods in the aerospace industry and highlights the necessary transformation of the industry in terms of sustainable and high-rate material and process technologies for the production of lightweight components in the field of advanced air mobility.

Lightweight design approaches and the demand for sustainable and recycleable materials for mass production have been door openers for a multitude of new applications for organo sheets in the automotive industry. In this lecture, a new series application and the challenges on the project's way to mass production will be shown.

Hollow parts reveal the best torsional stiffness to weight ratio and are the choice for various applications in the mobility industry. In the presentation an engineering route map is presented to numerically design, produce and test thermoplastic bicycle frames. With this approach many challenges of future mobility are addressed and solution for mass produced structural components are demonstrated.

• Rollercoaster: New mobility as a chance
• The human touch: Impact of resource scarcity and changes in consumer behaviour
• No way out: Impact of sustainability demands + regulations
(ESG, supply chain protection law, run out of ICE technology)
• The world is not enough: Global, regional, local - where to go, and how?

Advanced Air Mobility will soon revolutionise our mobility and AutoFlight is playing a key role in driving this development. With an international team and an exciting technical concept, AutoFlight has the potential to become one of the top players in the AAM market.

Cellcentric – a joint venture of Daimler Truck AG and the Volvo Group AB formed in 2021 - develops, produces and commercializes fuel-cell systems for use in heavy-duty trucks and other applications. Its ambition is Cellcentric, will introduce into the fuel cell technology and leads through the company’s journey from the first prototypes to the planned mass production.

By looking to make the best skateboard on the market, we worked out a manufacturing method that solves the three main problems of the composite industry: costs, production time and recyclability.
"Cost-Efficient Thermoplastic Endless Fiber-Reinforced Composite Sandwich With A Molded Foam Core
Via In-Situ Polymerisation With Recycled E-Caprolactam (PA6)"

Industrialization of a thermoplast composite re-enforced front end module.
High Level of Component Integration into Injection Molding Process reducing energy consumption due to eliminated post-assembly process steps. One shot injection molding process. Pre-cut organo sheets are inserted and formed in the injection molding tool combined with multiple additional inserts which are handled overmolded together to a complex composite hybrid.

The sustainable impact of origami construction on R&D costs, the production cost  of vehicles, performance and safety and the related vehicle Co2 footprint.

• full thermoplastic battery housings with functional integration
• integrated thermoplastic features to enhance cooling performance for HV batteries
• lessons learned and industry insights from concept/design/manufacturing and validation of IM components in battery enclosure/thermal systems

ENGEL will be showing the latest technology on the subject of recyclate processing - technologies from recycling extrusion integrated into injection moulding. The special processes on show offer numerous - additional - advantages. The processing of long glass fibre reinforced materials will be dealt with in particular.

Presentation of the process tape reinforced injection moulding; improvement of the mechanical properties through tape reinforced injection moulding; analysis of the environmental impact --> reduction of the GWP through reduced material use; presentation of the component and the process.

The lecture focuses on the overarching theme of "The Coming Structural Change" - the megatrends driving the change are "digitalisation and sustainability".
The 20s and 30s will be the most dynamic decades in human history and many established companies and industries will undergo massive change.
In focus: How is the mobility industry changing?

Topics:
• Multi modality
• New City Concepts
• Sustainability – CO2 Emissions and Fleet management
• New hardware – from cars to planes

Demystifying the mobility labyrinth.
Dirty, decrepit, wet, and aged roads are the reality of cities. Our solo journeys through metropoles often mean navigating century old networks designed for a different age and battling with thousands of other vehicles.
This is a far cry from the perfectly organized gleaming white and sun-streaked electric utopia’s that we seem to think we are designing for.
How do we design for the NOW without ignoring our obligation to up our game?

Global market outlook
Market and competive trends (disruptive challenges)
Potential implications for automotive suppliers