30th November - 1st December 2017
Hotel Palace, Berlin, Germany
Innovation in plastics for auto lightweighting
30th November - 1st December 2017
Hotel Palace, Berlin, Germany
Innovation in plastics for auto lightweighting
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DAY ONE - 30th November 2017


8.30 Registration and refreshments

9.30 Chairman’s welcome and introduction
Peter Fuß, Senior Advisory Partner, Automotive Team, Ernst & Young GmbH



9.45 Future trends in lightweighting
Speaker: Peter Fuß, Senior Advisory Partner, Automotive Team, Ernst & Young GmbH

  • The global market for automotive lightweight materials and how it has been rising exponentially over the last few years
  • The increasing need to improve the safety and fuel economy in cars and the enforcement of emission control rules and regulations
  • An overview of some of the material trends in lightweighting
  • The high cost of these materials and how it may limit their uptake in the near future, impacting the growth of the worldwide automotive lightweight materials market
  • The growth of autonomous vehicles and what that means for lightweighting cars



10.15 Semi-structural thermoplastic parts injected with “gas and water assisted process”
Speaker: Guillaume Gazonnet, Process Polymers Expert, Renault

  • The importance of connected functions’ integration, driving pleasure, comfort improvement and CO2 management of our future vehicles
  • How the potential weight lightening solutions will come partially from polymer materials and their associated transformation processes
  • Weight optimisation can be approached under single way (part to part) or by a combination of several parts and materials to preserve an acceptable level of industrial performance such as:
     - Part design
     - Material behaviours
     - Transformation process
     - Assembly process
     - Results and opportunities that gas and water assisted injection can give us to develop large semi structural parts, mixing low and high thicknesses with an optimized stiffness

11.00 Morning refreshments and networking

11.30 High definition fibre optic sensing and the benefits it brings to lightweighting and electric vehicles
Speaker: Ian ShannanEMEA Director of SalesLUNA

  • Environmental concerns and increasingly stringent government regulations
  • How these are driving the automotive industry towards the use of new lighter weight material systems and an electrification of vehicle drive trains
  • The new design challenges created by these trends that in turn will require new advanced methods for test, measurement and validation
  • The advantage of high definition fibre optic sensing technology to help automotive manufacturers speed these new technologies to market while lowering the risk associated with the introduction of these new materials and processes

12.00 Nonwovens and composites: achieving lightweighting and improved acoustics

Speaker: George Kellie, DirectorKellie Solutions Ltd

  • How there are two strong parallel drivers in automotive materials developments; lightweighting, acoustics
  • Achieving both targets is not easy particularly at a time when automotive designs and powertrains are going through major change
  • Why the topic is therefore timely
  • Key points:
    - Market trends, acoustic nonwovens and composites
    Latest steps in lightweighting
    Impact of powertrain changes
    Examples and market forecasts


12.30 Thermoplastic composite lightweighting: an innovative automotive sunroof system within an innovative circular business model
Speaker: Sem Sals, Product Development Engineer, Polyscope Polymers BV

  • Driven by innovation and a low-carbon economy; an ambition to co-develop a Sunroof Frame (SRF) system with focus on:
    - Lightweight and optimal functionality integration
    - Potential use of recycling materials
    Creating a sustainable platform structure which offers long term, circular economy services and packages
    - How the partnership is strongly linked to CLAUT (Circular Automotive platform).


13.00 – 14.00 Lunch and networking



14.00 Online data collection and modeling for the adaptive production of composite pipes and vessels
Speaker: Martin SchäkelResearch FellowFraunhofer Institute for Production Technology IPT

  • Examining the new development of winding technology for the production of composite pressure vessels for the automotive industry out of unidirectional fibre-reinforced thermoplastic tape.
  • The ambliFibre project, funded within the European Horizon2020 framework and coordinated by Fraunhofer IPT
  • Targeted data collection and utilization during the production of composite pressure vessels to optimise the process and provide the basis for such a model-based controlled system

14.30 Acoustically absorbing lightweight thermoplastic honeycomb panels
Speaker: Thomas Herdtle, Advanced Research Specialist, 3M

  • How the sandwich principle of stiff facesheets bonded to a lightweight core is a very efficient structure for rigidity per unit weight and has been used extensively in airplanes for over fifty years
  • The development of novel thermoplastic composite sandwich panels that may be heated and shaped by compression molding or thermoforming
  • Recyclability of these panels at the end of their service life
  • The challenges of maintaining the same level of quietness in the vehicle interior as vehicles become lighter; a look at acoustic absorption


15.00 Afternoon refreshments


15.30 Innovation discussion
Alexandre Rossier, Transportation Design Projects Leader, KISKA
Bert Havenith, Strategic and Market Intelligence Director, DSM Engineering Plastics
Anja C. Rohmann, Application Engineering Specialist, Vehicle Lightweight Solutions, 3M

16.15 ThermHex organosandwich honeycomb preforms for automotive applications
Jochen Pflug, Managing Director, ThermHex Waben GmbH / EconCore N.V. 
  • The weight reduction and cost saving potential of sandwich construction with thermoplastic honeycomb cores
  • The continuous production of thermoplastic honeycombs and thermoplastic sandwich preforms
  • The further processing of thermoplastic sandwich preforms with injection moulding for automotive applications

16.45 Tailgate part in Composite Hybrid Thermoplastic - a way to go?
Speaker: Geert-Jan Doggen, Automotive Marketing, SABIC

17.15 Chair summary of the day

17.30 Networking drinks reception for all attendees


DAY TWO - 1st December 2017

8.30  Registration and refreshments

9.00  Chairman’s opening remarks
Alexandre RossierTransportation Design Projects LeaderKISKA



9.15 Rethinking lightweight vehicle architecture in the face of e-mobility and autonomous technology
Speaker: Alexandre Rossier, Transportation Design Projects Leader, KISKA

  • Autonomous and e-mobility technologies are having a powerful impact on vehicle architecture and design
  • The technologies are challenging designers to explore alternative interior configurations and alter the interaction experiences for both “drivers” and passengers
  • In terms of lightweight construction, advantages and challenges will no doubt arise alongside these new paradigms. Designers will be compelled to investigate materials and construction that are more authentic to a vehicle’s function
  • How brands respond to the opportunities presented by autonomous and e-mobility technologies right now will speak volumes about them decades down the road


9.45 The growth and future prospects of L Category vehicles
Speaker: Professor Peter Wells, Professor of Business and Sustainability, Centre for Automotive Industry Research, Cardiff Business School

  • ‚ÄčAn introduction to the growth and future prospects of the L Category (vehicles with less than four wheels) segment around the world
  • How this is tied up with the future fortunes of the automotive industry and the penetration of battery electric traction
  • How this is a distinctly 'unglobalised' segment ranging from EU quadricycles; Indian Rickshaws, US NEVs, and Chinese Low-Speed Electric Vehicles


10.15  The next leap in metal-to-plastic conversion with new high-performance plastics from DSM
Speaker: Bert HavenithStrategic and Market Intelligence Director, DSM Engineering Plastics

  • Metal-to-plastic conversion for light weighting and system cost reductions in automotive
  • How a next step-up in metal replacement is now possible via new high-performance plastics
  • Relevant value propositions for the different components will be elucidated for specific customized grades

10.45 Morning refreshments and networking

11.15  Replacing die casting aluminium components with lighter plastic-metal hybrid solutions
Speaker: David Martinez Llanos, Chief Technology Officer, Teknia Group

  • From design to over-moulding: understanding the process of manufacturing plastic-metal hybrid parts
  • Metallic core with over-moulded plastic configuration advantages: lighter and cheaper solution
  • Potential parts to be replaced in the automotive sector: a look to future developments, saleability and customer benefits


11.45 Sustainability in automotive with reclaimed materials
Speaker: Dr. Joseph J. Laux, Global Director of Material Science, Magna Exteriors, Magna

  • An introduction to the use of reclaimed materials
  • Advantages in weight reduction opportunities using reclaimed carbon fibre materials
  • Future visions of the use of these materials


12.15 Weight reduction by foaming in injection molding 
Speaker: Andreas Kürten, Managing Director, KIMW Anwendungstechnik GmbH

  • Comparison between chemical and physical foaming
  • What is needed
  • What is achieved
  • What are the advantages and the disadvantages
  • How to control the quality of the foamed parts
  • What to do in future where are the chances and where are challenges

12.45 – 13.45  Lunch and Networking

13.45 Lightweight Technology Solution for Interior Trims: Natural Fiber Polypropilene (NFPP) Technology
Speaker: Dr. Paola Bruno, Materials Engineer, Project Development Center, Grupo Antolin
  • NFPP Technology Overview
  • NFPP Series Application at Grupo Antolin
  • State of Art: Concept NFPP One Step – Pressing & Back Molding (Technology Overview, Test Results)
  • Weight/Cost comparison for different DP concept
14.15 JetPreg, the innovative Cannon spray-on-honeycomb solution for lightweight semi-structural automotive components
Speaker: Alessandro Colella, Sales Engineer, Cannon Afros
14.45 Afternoon refreshments and networking
15.15 Panel discussion: What are the challenges in creating multi-material components and systems for weight reduction in cars?
Professor Peter Wells, Professor of Business and Sustainability, Centre for Automotive Industry Research, Cardiff Business School
Andreas Kürten, Managing Director, KIMW Anwendungstechnik GmbH
16.00 Chair summary of the day and close of conference

Programme may be subject to change

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