www.chemicalsknowledgehub.com


substantially reduce the need for material testing and design iterations.


AM could also become invaluable in personalizing cars. Mass customization is already here, with buyers choosing colour, engine size and type, interior trim, and ‘infotainment’ systems, but they still have to select these from a relatively limited set of options. With AM, customers can build truly unique cars at only moderate extra cost. For example, BMW’s ‘Mini Yours Customize’ car lets Mini users personalize exterior indicator inlays, passenger-side interior trim, LED door sills, and door projectors, all with a mobile app. These parts are then produced at BMW’s Additive Manufacturing Center in Germany.


The practical implications of this are enormous. For instance, currently, car makers must hold significant stocks of all sorts of spare parts for a minimum of ten years. This is expensive and unwieldy. Major companies and their distributors have warehouse shelves stretching for countless miles holding components that may never be called for. With AM, those components could be produced only when they are needed – anywhere in the world. But AM can also have major


advantages for niche players. Take Briggs Automotive Company (BAC), a car manufacturer that builds limited-edition, personalized supercars. BAC was able to shorten production times and cut the cost of part production by more than 50% using 3D printing technology.


Summer 2020


DSM collaborated with BAC to transform the manufacturing process of its Mono R model, resulting in lightweight, high- performance, custom-made parts. But how well do DSM’s AM


materials perform? In fact, its printing materials are toughly tested in Formula 1 vehicles. AM allows teams to quickly test different design concepts,as multiple design variations can now be built at the same time, reducing product development cycles. On top of that, new computer-aided engineering technology helps DSM test materials in the lab. Predictive modeling,for example,can simulate parts’ performance under stress even before printing. Indeed, DSM’s collaboration with e-Xstream on predictive fatigue modeling for reinforced polyamide parts will


Making refinishes more efficient But that’s not all there is to manufacturing. Did you know that the most energy-intensive (and cost-intensive) process in car manufacturing is the painting of the car? The best car refinishes are efficient, sustainable, and durable. But this means that, traditionally, they consist of multiple layers, each with multiple properties and often based on a variety of resins. Unless, of course, you open up


DSM’s scientific toolbox. Indeed, DSM’s scientists have found a way to develop high-end car refinishes with excellent adhesion and hardness while enabling car manufacturers to reduce the spray booth cycle time from 30 to 15 minutes at 60°C, ready to polish after cooling down. In normal conditions, this represents a productivity increase of about 20%. In other words, with smart refinishes, additive manufacturing and bio-based materials, we’re on the road to redesigning not just the car, but the entire automotive industry.


Connecting the car of the future Finally, when it comes to connecting the car of the future,


Automotive Industry


the move towards connectivity in the automotive world might just be as big as the transition to greener cars. We’re seeing new standards for car usability, with autonomous driving being the most obvious. Meeting the extreme demands of these next-generation cars requires designers to re-think and reimagine what’s possible, as we see two entirely different industries – automotive and electronics – converge. You may have heard of ‘thinnovation’– the trend for making working parts in electronic devices such as mobile phones smaller, lighter, greener, and safer.The materials supplied by companies like DSM are used to create these components. Tomorrow, these same materials (and their descendants) will do a similar job in cars, as we discover smart new ways to integrate electronics into plastic materials. With knowledge and experience of both mobile phones and automotive applications, DSM is well placed to connect with partners worldwide to create something truly remarkable.


Green cars for all


Above all, to enable these automotive industry transformations, OEMs will need suppliers that don’t just understand materials, but also application challenges. DSM’s approach is set to lead the way: dedicated R&D teams work closely with industry experts and engineers to look at the entire process of developing new parts and components – from design and material performance to production and compliance. With this kind of collaborative approach, parties across the automotive value chain can build a brighter future for the car industry – a future where mobility does not harm the world around us. More than ever, it’s time to deliver on Ford’s pioneering vision, and make green cars available for all!


Further information E: www.linkedin.com/in/ marcusremmers/


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