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Automotive

Composites play a vital role in their potential to reduce vehicle mass. Whether for increased performance in the motorsport, luxury and premium segments, higher fuel economy for combustion vehicles, or weight offset and increased range for the fast growing battery or hydrogen market, composites are displacing metals as cost and production rate challenges are solved.

Why are composites important for the automotive industry?

Superior structural properties for performance vehicles
Lower cost tooling reducing “legacy” investments

Enabling next generation of electric vehicles
Lightweight or lower weight vehicles for a more sustainable future

How can Airborne help automate production in the Automotive sector?

Airborne can provide support in many ways depending on your stage of development and current challenge.

In all Automotive segments there is a drive to improve the competitiveness of composites to reduce finished part costs, minimise waste, lower weight, improve total cost of ownership, and achieve the production rates necessary. Our team of engineers has experience in matching different materials and manufacturing processes to achieve functional and economic challenges presented by OEMs and tier suppliers. We understand thermoset and thermoplastic options, tooling technologies and trade-offs, RTM vs compression moulding, and can provide support at the design, prototyping, manufacturing or scale-up phases of your project.

Thermosets

The automotive market has developed a wide range of material solutions to meet the variety of needs for weight saving and cost. Glass SMC is well established in Automotive composites and Airborne can assist with pick and place of SMC charges. At the higher cost end, both RTM and compression moulding carbon processes use webs of material with shapes cut out. The minimisation of waste, improving yield, cost and achieving production rates are continually improving the competitiveness of these technologies through the use of integrated kitting to maximise material nesting while managing the greater kit complexity which comes with it. Pick and place, and automated preforming transform these plies into tailored blanks suitable for high rate processing.

Thermoplastics

End of life recycling, cost sensitivity and design flexibility have driven the growth of thermoplastics in Automotive however the need for a new paradigm in electric vehicles has increased the attention to these materials. With possibilities for overmoulding thermoset structures, fibre reinforced versions reducing CTE issues, and fresh thinking, thermoplastics look set to grow significantly. Airborne have deep knowledge in processing both high and low performance thermoplastics through the Oil & Gas development of a continuously wound thermoplastic riser. Airborne’s Falcon line demonstrates the technology for very high rate production of thermoplastic laminates.

What services and automation solutions are there for the Automotive market?

Before commitment to a new program, understanding the match between functional requirements, economics and volumes is critical. Airborne can offer support to evaluate different options. Once the product is designed and proven, our range of automation solutions can be implemented at your facility or a chosen tier supplier. Airborne textile handling solutions are designed with the Automotive market in mind to minimise material waste, labour costs, and achieve high rate takt times.

21^st century manufacturing requires

…the integration of automation and digital technologies, so called “Industry 4.0”. Airborne are developing digital tools that combine with automation to enable the digital thread through the supply chain, integration with MES & ERP systems, automated programming, digital twins, and data collection for operational insights. This vision for future manufacturing combined with composites know-how sets Airborne aside and why we consider ourselves long term partners not just suppliers