Use of Carbon Fiber Components in the Automotive Industry 2012


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This report gives a brief overview on the usage of carbon fiber components in the automotive industry, including goals, challenges and a case study.

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Use of Carbon Fiber Components in the Automotive Industry 2012

  1. 1. Use of Carbon Fiber Components in the Automotive Industry 2012 Goals, Challenges, and Case StudySlide 1 © Contrium Research GmbH 2012. All rights reserved.
  2. 2. Find out more…Reduction of CO2 emissions has become a strategictarget of the automotive industryDRIVERS AND EFFECTS OF CO2 STRATEGIES CO2-emissions [g/km] Legal requirements regarding fleet XXX consumtion YYY Increased sales taxes ZZZ and prices for gas/fuel Life cycle Fleet consumption considerations Selected models2 2004 2005 2006 2007 2008 2009 2010Slide 2 © Contrium Research GmbH 2012. All rights reserved.
  3. 3. Find out more…BMW has started its “Project i”, targeting significant weightand subsequent CO2 reductions by using CFC1BMW’S “PROJECT I” AND KEY SUCCESS FACTORS IN LIGHTWEIGHT CONSTRUCTION WITH CFC Vision: Large scale production of electric mobility using CFC lightweight  200x: Project kick-off (project lead directly reporting to XXX)  Mid 200x: Decision on CFC as Ability to produce preferred material for XXX and XXX on a large scale parts, as well as XXX as preferred supplier Capable XXX Key  Mid 200x: Clearance of major suppliers success investments (among these XXXmEUR factors CFC light- for a JV with XXX and new assembly weight construction lines in XXX)  Early 200x: Creation of a new brand Competitive for those cars being developed in manufacturing XXX course of Project i: „BMW i“ costs  200x: Forecast launch of „BMW XXX“ (sales price estd. 40.000 EUR) and „BMW XXX“1 CFC = Carbon Fiber Composites; CF = Carbon FiberSource: BMW website, press releasesSlide 3 © Contrium Research GmbH 2012. All rights reserved.
  4. 4. Find out more…Within their “Project i”, BMW makes use of their substantialin-house carbon fiber competencyBMW “PROJECT I”, INITIAL STEPS  In XXX, BMW started to set up own technology for components  Development of basic concepts, production processes and quality standards with up to XXX employees  Small-scale production of Find out more… components with XXX-material from XXX in their Landshut plant (e.g. BMW M6 using CC XXX and CC XXX)Source: BMW press releasesSlide 4 © Contrium Research GmbH 2012. All rights reserved.
  5. 5. Find out more…BMW invests heavily to ensure the security and stability ofits carbon fiber supply chainBMW “PROJECT I” – MATERIAL SUPPLY CHAIN Carbon Precursor Fabrics XXX XXX Assembly fiber Joint Joint BMW-owned component New BMW Joint Venture Venture XXX Venture XXX manufacturing in production XXX and XXX and BMW and BMW XXX and XXX in XXX (USA) (GER) XXX mEUR XXX mEUR XXX mEUR XXX mEUR (51:49) (51:49) (Budget until 2013) Special know-how: Special know-how: XXX XXX Total Invest XXX mEUR1 XXXSource: XXX/BMW Press ReleasesSlide 5 © Contrium Research GmbH 2012. All rights reserved.
  6. 6. Find out more…However, other major players have started to followJOINT CF PROJECTS IN THE AUTOMOTIVE INDUSTRY (EXAMPLES) Find out more…  Joint Venture (started  JV for XXX/component  Letter of intent signed to XXX) production (XXX) establish a development  Products: XXX materials  XXX has broad partnership (XXX) and components experience with the raw  Objective: Production of  XXX: XXX and material, mature XXX materials and development of XXX production processes and development of a highly processes know-how automated process chain  XXX: XXX design and XXX  Optimized and for large-scale production  Objective: competitive, guaranteed material  XXX has a CFC XXX time supply by XXX competence center at  Usage of CF components  XXX has, as a classical Tier XXX in Mercedes XXX in XXX 1, XXX  XXX has years of  Prototype production in experience in XXX XXX(acquisition of XXX) production with XXX(XXX)Source: XXXSlide 6 © Contrium Research GmbH 2012. All rights reserved.
  7. 7. Find out more…BWM learnings: some factors are critical for successCRITICAL SUCCESS FACTORS FOR USING CFC XXX and stable quality standards are crucial. Manufacturing costs have to be reduced to target costs. XXX production is more crucial than just XXX production. Find out more… Serial mass production of CFC requires far more capabilities than production of small volumes. Current supplier situation does not fulfill the requirements of XXX. BMW XXX as a consequence. Close cooperation between XXX and XXX is essential. XXX alliance recommended.Source: BMW press releasesSlide 7 © Contrium Research GmbH 2012. All rights reserved.
  8. 8. Find out more…Two major issues have to be addressed in CFCISSUES OF CFC 1 Manufacturing costs to be reduced 2 Appropriate supply chain required Production costs structural components Carbon fiber Com- [EUR/kg](estimates) XXX XXX fabrics ponents XXX So far, no comprehensive Ability to Producer XXX concepts set-up a expertise Capable suppliers limited XXX existing XXX XXX but available XXX XXX XXX Target costs < XXX < XXX ~XXX >XXX pieces pieces pieces pieces Other critical issues: XXXSource: Primary interviewsSlide 8 © Contrium Research GmbH 2012. All rights reserved.
  9. 9. Find out more… 1CFC manufacturing costs must be reduced at least byXX%REDUCTION OF CF COMPONENT COSTS [EUR/KG] (ESTIMATES ONLY!) Stage 1 Stage 2 (immediate actions) (economies of scope)  Decreased raw material costs XXX  Improved XXX, integrated facilities with XXX XXX  Economies of scale  Decreased energy costs  Enhanced XXX properties, improvement in consistency Open question:  XXX cost gap too large? XXX XXX XXX ~XX Current costs at Mid-volume Target costs Classic steel XXXSource: Primary interviewsSlide 9 © Contrium Research GmbH 2012. All rights reserved.
  10. 10. Find out more… 2Several hundred million Euro of investments may be savedby optimizing the supply chainREQUIRED INVESTMENTS IN PRODUCTION EQUIPMENT BMW VS. BEST CASE (ESTIIMATES ONLY!) Carbon Precursor Fabrics XXX XXX Assembly fiber Joint Venture Joint Venture BMW-owned component New BMW Joint Venture XXX and BMW XXX and BMW manufacturing in XXX production XXX (USA) (GER) and XXX in XXX BMW XXX mEUR XXX mEUR XXX mEUR ∑ XXX XXX mEUR1 (51:49) (51:49) (Budget until XXX) mEUR  Strategic partnerships, e.g. Selection of partners key  Utilization of XXX infrastructure  Consideration of well-established success factor  Optimized procurement of machinery and tools foreign companies Best case Find out more… (Alliances with machine manufacturers)  Alliances with newcomers (assumed solid  Outsourcing of XXXmanufacturing financial basis and low energy costs) (Partnerships with XXX producers in XXX) ∑ XXX XXX EUR XXX EUR XXX EUR XXX mEUR mEURSource: SGL/BMW press releases , primary interviewsSlide 10 © Contrium Research GmbH 2012. All rights reserved.
  11. 11. Find out more…From a lifecycle perspective, carbon fiber production andrecycling are critical in terms of CO2 emissionsCF LIFECYCLE PERSPECTIVE: CO2 EMISSIONS  Issues in XXX XXX regarding precursor Carbon fiber  Inefficient chemistry in CF production production1  Large amounts of XXX as a byproduct of CF production  XXX requires significant amounts of energy input Carbon fiber • CO2 emissions tolerable processing2 • Comparably low CO2 emissions in usage phase due to high XXX in combination with low weight Usage • Significant advantages to other materials, e.g. metals, glass fiber • Difficulties in XXX of CC • CC is outperformed by XXX Recycling1 Represents value chain steps “precursor” and “carbon fiber”2 Represents value chain steps “fabrics”, “preforming”, “molding/finish” and “assembly”Source: Primary interviewsSlide 11 © Contrium Research GmbH 2012. All rights reserved.
  12. 12. Find out more…The exact trade-off between CC production and use in theautomotive sector is being discussed controversiallyBREAK EVEN CO2 EMISSIONS OF CC CARS CO2 trade-off in the automotive sector Different CO2 break even scenarios [driven 1,000 km](CC employment vs. traditional manufacturing) „Using CC in automobiles pays off after … kilometers have been driven!“ XXX Higher CO2 Less CO2 emissions emissions than steel due to CC Pessimistic Moderate Optimistic CC production CC usageSource: Primary interviewsSlide 12 © Contrium Research GmbH 2012. All rights reserved.
  13. 13. Find out more…There are different approaches to assess eco-efficiencyOVERVIEW OF DIFFERENT APPROACHES (EXEMPLARY) KPI Applicable regulations/ Description (common) standards1 Carbon accounting is the accounting process undertaken to measure the amount of carbon dioxide CO2-balance/ Carbon Tons CO2 (or equivalents) equivalents that will not be released XXX accounting into the atmosphere as a result of flexible mechanism projects under the Kyoto Protocol Fleet consumption describes the average fleet consumption of a car Fleet consumption g(CO2)/km XXX fleet (all Find outa company, vehicles of more… producer or of a vehicle class) LSA is a technique to assess environmental impacts associated with all the stages of a products life Ecobalance/ Life cycle from-cradle-to-grave (i.e., from raw Diverse XXX assessment (LSA) material extraction through materials processing, manufacture, distribution, use, repair and maintenance, and disposal or recycling)1 Exemplary2 World Business Council for Sustainable Development and World Resources Institute3 XXXSource: Primary interviewsSlide 13 © Contrium Research GmbH 2012. All rights reserved.
  14. 14. Find out more…The Greenhouse Gas Protocol (GHG) guidelines provide ageneral framework for assessing CO2 emissionsPOSSIBILITIES IN CO2 ACCOUNTING – GHG (EXAMPLES) Organizational possibilities Operational possibilities Possibilities in calculation Different approaches can be Emissions can be classified in Emissions can be calculated used to consolidate GHG different categories and using different approaches emissions calculated/reported  Direct measurement of GHG  XXX approach: a company accordingly emissions accounts for GHG emissions  Scope 1: XXX  Application of documented from operations according to  Scope 2: Electricity indirect emission factors its share of equity in the GHG emissions of purchased operation  Calculation from fuel use electricity data  XXX approach: A company  Scope 3: XXX accounts for 100 percent of Calculation methods often the GHG emissions from differs according to scope operations over which it has  XXX: Calculation from internal control (financial or data operational)  XXX Calculation primarily from activity data and published or third-party emission factorsSource: The Greenhouse Gas ProtocolSlide 14 © Contrium Research GmbH 2012. All rights reserved.
  15. 15. Find out more…Disclaimer This report has been prepared and sold by Contrium Research GmbH, Hamburg (Germany) (“Contrium Research”) under its brand “anditsmarkets”. It is solely addressed to the buyer of this report. This report is for information purposes only and is sold on a non-reliance basis only. Therefore, the buyer of this report is not entitled to rely upon the contents of this report. By buying and using this report, the buyer agrees on the terms and conditions set forth in this disclaimer. The data, estimates, interpretations, assessments, and projections (together “the information”) contained in this report have been collected from sources deemed to be reliable. The information contained in this report can change over the course of time and may even already have changed by the time the report is being bought by the buyer. The information contained in this report involve significant elements of subjective judgment and analysis and, by nature, may prove to be wrong. The information contained in this report is not claimed to be complete or to represent all the information that the buyer of the report might desire with regard to a specific topic he is interested in. Each buyer of this report should therefore conduct his own independent analysis and research of the topics covered in this report before taking any decision. Although this report has been prepared in good faith, Contrium Research, its shareholders, and its managers under no circumstances make any representations or warranty, express or implied, as to the accuracy or completeness of the information contained in this report; and the recipient acknowledges that he may under no circumstances hold the above legal entities or individuals liable on the grounds that one or more items of information contained in this report are revealed or healed to be insufficient, incomplete, imprecise or inaccurate.Slide 15 © Contrium Research GmbH 2012. All rights reserved.