"(IT'S NOT EASY) BEING GREEN" -
A HOLISTIC APPROACH FOR A SUSTAIN
PRODUCT DEVELOPMENT PROCESS
3 rd June 2020, 9:00 – 10:00, Webinar of Composites United e.V.
Speaker: Markus Beer, Forward Engineering GmbH
Forward Engineering will show the development framework “Design for Sustainability” with examples of
applications how to adopt the methodology to your product portfolio.
FORWARD ENGINEERING PRESENTS AT THIS YEAR´S
“STRUCTURAL THERMOPLASTIC COMPOSITES
The first Virtual Thermoplastic Composites Conference (TCC2020), presented by ACMA and
Composites Manufacturing was a great and interesting online experience.
Our presentation on Accelerating the Deployment of Structural Thermoplastic Composites for Next
Generation Automotive and Transportation Applications was received very well with excellent questions
from the engaged audience of participants.
Strong interest in collaboration around Material Card generation and sharing was a key take-away from
the event. Forward Engineering’s Material Card Development Program was designed exactly for this
reason and we are excited to play such an important role in the growth of structural thermoplastic
Meeting with exhibitors and attendees through the online platform and the live feedback through the
chat function during the presentations was a unique way to measure audience engagement real time.
Thank you to the ACMA and everyone that participated in this very special event. We look forward to
continuing the very interesting discussions around accelerating the growth of Structural Thermoplastic
Composites and welcome those we have yet to connect with to contact us directly to join the
SUCCESSFULL DEVELOPMENT OF COMPOSITE
DOMINATED MULTI-MATERIAL CAR
PLATFORM FOR CHANGAN.
The Chinese vehicle manufacturer CHANGAN has successfully produced the 1st government funded
composite dominated multi-material car platform in its Chongqing factory on March 20th 2020.
Our subsidiary, KDX Design Center was responsible for engineering development of the body in white
& closures from pre-study phase to final data release incl. strong support for all material, process
and assembly related topics.
The body structure consists of 2 modules – with the upper made mainly from CFRP incl. high
strength steel and lower frame made entirely from aluminum.
The major challenge of this fast lane development project is to achieve a robust design within short
development period and at the same time to meet high weight-performance targets (over 30%
lightweight to metal, 5 stars CNCAP rating). In addition, over 10 different local materials and 4
manufacturing technologies need to be qualified and used for body structure, which requires full
understanding of different material behaviors and specific material development strategy [MODULAR APPROACH ©FE].
The vehicle structure has been validated by FEA simulations and several tests including full vehicle crash tests.
After the entire vehicle validation tests and further optimizations, the multi-material structure
concepts are expected to be transformed into mass production applications at CHANGAN Group.
NEW SMC MATERIAL ENABLES ECONOMIC
LIGHTWEIGHT CONSTRUCTION OF BATTERY ENCLOSURES
In cooperation with its joint venture Vestaro, Forward Engineering has developed a multi-material design
for a battery enclosure. The central component is the cover structure, which is based on the Sheet
Molding Compound (SMC) technology. By using a specially developed hardener for epoxy SMC systems
from Evonik, a cost-efficient and mechanically highly resilient lightweight design could be realized. In
cooperation with the manufacturing partner Lorenz Kunststofftechnik and the battery system developer
LION Smart, this development was presented and validated within a holistic battery system concept. The
preliminary project results were published in the JEC Magazine (issue 133).
FORWARD ENGINEERING EXPANDS GLOBAL
TEAM WITH THE ESTABLISHMENT OF FORWARD
ENGINEERING NORTH AMERICA
We are proud to announce the establishment of Forward Engineering North America, LLC (FENA)
and the appointment of Adam Halsband as Managing Director of our North American Operations.
The Forward Engineering team has been supporting North American clients and collaborating with
regional technology partners on the accelerated adoption of composite intensive mixed material
solutions since several years. Electrification, automation and demand for cost effective innovation
has fueled a steadily increasing demand for FE’s unique production-based design and engineering
services in the North American market.
With our new office in Metro Detroit and a dedicated team on site we are now even closer to our
customers and partners to support the growth of Forward engineering globally and especially in
the North American market.
Read the official press release here:
FORWARD ENGINEERING PARTICIPATES AT THE JEC
WORLD EXPO PARIS FROM MARCH 3RD TO 5TH AND
SHOWCASES BATTERY ENCLOSURE DEVELOPMENT.
Achieving the optimal balance of Mass/Cost/Performance is critical to the adoption of advanced
materials and manufacturing processes in the very competitive automotive industry. Forward
Engineering team members will be presenting the fundamentals of battery enclosure to vehicle
structure integration as well as case studies demonstrating the potential for cost effective
lightweighting with composite intensive mixed material solutions.
“Electrification presents a unique challenge for the transportation industry and the opportunity for
Forward Engineering to support our OEM and Supplier partners with development and validation of
some of the most exciting new composite intensive mixed material designs.” Stated Robert Maier
– Managing Director. “We are looking forward to share those stories with visitors to the JEC World
in Paris this year.”.
Please stop by our exhibit at Composites in Action Hall 6 Stand D85 to learn more.
WOVEN ROOF BOW WINS 1ST PLACE AT THE CHINA LIGHTWEIGHT DESIGN AWARD
Our joint venture, KDX Design Center, has developed a braided composite roof bow for the Chinese vehicle manufacturer BAIC. KDX DC was responsible
for concept development, material and technology selection, material characterization and supplier management.
The jury was impressed by the load-path design with cost-efficient material selection (CF and GF), the coreless braiding structure, hybrid joining
and the variable cross-sections for flexible interfaces, as well as by the technical performance data (weight: -36.5%, compressive strength: +10%,
flexural strength: +60%, torsional stiffness: 10-fold, costs: -50% compared to the industry average) of the fiber composite roof bow.
In the end, 5000 professionals and 7 industry experts awarded the project with the
More information at:
KDX DESIGN CENTER NOMINATED FOR NIO LIGHTWEIGHT CARBON FLOOR AT JEC INNOVATION AWARD 2019
Anew we can proudly announce that our Chinese production partner Kangde Composites Co, Ltd (Langfang, China) KDC together with
our joint venture KDX Roding Europe Automobile Design Center GmbH (Munich, Germany) and two other partners are once
again among the finalists for the JEC Award 2019 in the category "Automotive Application".
This year we are nominated for the innovative NIO Composite Floor of the NIO ES6, which was created through the close cooperation of
a global network of experts. Despite its low weight (>30% weight saving compared to Al baseline) it offers outstanding vehicle performance
(torsional stiffness 44,930 Nm) with 5-star NCAP safety. Furthermore, it can be produced cost-efficiently in high volumes due to a low cycle
time (2.5 min) and a fully automated process.
Whether we can take the price for our NIO Composite floor home with us, we will find out on March 13 at this year’s JEC World in Paris. We are excited!
More information at:
FORWARD ENGINEERING PRESENTS AT THIS YEAR´S
SPE ACCE IN NOVI, MICHIGAN
This year’s Annual Society of Plastic Engineers Automotive Composite Conference & Exhibition took place on September 5-7, 2018 in Novi, Michigan:
Together with our North American Representatives, Ruhl Strategic Partners, Forward Engineering presented the
“Modular Approach to Material Card Generation Accelerating Composite Part Development”
which provided a clear roadmap to overcoming one of the key barriers to the inclusion of composites in vehicles today.
Concurrent with our technical presentation, the Forward Engineering expo hall booth featured their new CF-SMC One Piece One Shot Wheel for Urban Mobility Vehicles.
Over the course of the three day event there was a continuous flow of visitors from across the industry and around the world.
Our team had an excellent time sharing insights about Forward Engineering’s Production Based Engineering programs and exploring opportunities to accelerate the development
of innovative composite intensive solution for the automotive industry.
We are looking forward to working together with these wonderful new connects and the opportunity to participate in SPE ACCE 2019!
FORWARD ENGINEERING OPENS DEVELOPMENT SITE IN JAPAN
On June 1st 2018, the establishment of “Forward Engineering Japan Co., Ltd.” marked another important milestone in the growth and internationalization of Forward Engineering.
The establishment of a branch for Sales and Engineering is the consequence of the success of our team in Japan in the past years.
With the new location in Nagoya, we will be able to serve our customers and technology partners in the important Japanese and Asian automotive markets even better and more directly.
Read the official press release here:
FORWARD DESCRIBES CHARACTERIZING
Due to the amount of a composite’s parameter and the still low confidence regarding crash performance, the potential of this material cannot fully be used.
The in 2016 initiated partner project of Forward Enineering GmbH, Hexion GmbH and Zoltek Corporation was aimed at decreasing the entrance barrier
into composite structure development for automotive industry in early component development phases.
The result contains a modular methodology for the creation of material cards for the simulation of structural components,
which cosiders the following aspects:
- Comparability, time and cost reduction by means of standardization of material characterization and coupon production
- Use of etablished industrial materials for mass production as a representative starting material for the early development phase and structure simulation
- Free provision of Module 1 mechanical properties for our customers and partners and, in conjunction with an engineering project, also Module 2 properties
- Fast determination of the overall crash performance of a material without complex testing
- Acceleration of early development phases and decision processes by parallelization of design and CAE verification and thus, cost reduction during development
In addition to the freely available methodology, the developed material card (LS-Dyna, incl. post failure)
will be provided to customers right in the beginning of a project.
A detailed description can be found in the current issue of ‘Lightweighting World’ following the link
KANGDE COMPOSITES KDC AND KDX DESIGN CENTER
ARE NOMINATED FOR THE JEC INNOVATION AWARD 2018
We are proud to announce that our Chinese production partner
Kangde Composites Co, Ltd (Langfang, China) KDC together with our Joint Venture KDX Roding Europe Automobile Design Center GmbH (Munich, Germany)
are one of the finalists nominated by JEC Group (Paris, France)
for the JEC INNOVATION AWARD 2018:
Category: Automotive Application
- DEVELOPMENT AND MANUFACTURING OF A FULL - CFRP CAR BODY – for Fastar New Energy Automobile (China)
A reowned jury of experts will select one winner per category out of the 30 award finalists divided into 10 categories.
The 10 winners will be announced in a ceremony to be held at JEC World 2018 on March 7, 2018 in Paris.
FORWARD AT IPF IN JAPAN
Forward Engineering will showcase this year on 5 days (Tuesday, 24. October to Saturday, 28. October 2017)
at the IPF Japan - INT´L PLASTIC FAIR in Chiba.
In a special sideshow "Composite Materials", organized by NCC and ICC at Booth No.: NCC-15, Hall 4 (NCC Zone)
visitors can obtain comprehensive information about the latest developments, trends, services and products from Forward Engineering.
At Asia's leading trade fair for plastic and synthetic material international exhibitors, including the world leaders in the industry,
meet and demonstrate innovative products and machinery.
FORWARD ENGINEERING PRESENTS AT THE SPE ACCE
The 17th Annual Society of Plastic Engineers Automotive Composites Conference & Exhibition “Worlds Leading Automotive Composites Forum”
took place 6-8 Sept 2017, Novi, Michigan.
Forward Engineering presented together with our new North American Representatives Ruhl Strategic Partners:
“Simulation Driven Design: Enabling & Accelerating Lightweighting”
This world class event provided the opportunity to share with key stakeholders from OEMs, Tier Suppliers and Technology companies how
Forward-Engineering’s unique Production Based Engineering capabilities Enable & Accelerate Lightweighting in the Automotive Industry
The event was a tremendous success including three intense days of presentations, exhibit hall activities and post show networking meetings.
“The level of engagement and urgency in the North American market was clear to see…” said Adam H. “…and the range of very interesting questions made it clear
key industry players value the unique capabilities that Forward-Engineering delivers.”
KDX EUROPE COMPOSITES R&D CENTER FOR LIGHTWEIGHT CONSTRUCTION WAS
OPENED IN WEYARN BY BAVARIAN MINISTER OF ECONOMIC AFFAIRS ILSE AIGNER
On June 6th 2017, the Joint Venture Partner of our affiliated company KDX Roding Europe Automobile Design Center has opened the
new KDX Europe Composites R&D Center with an official ceremony in Weyarn.
About 300 guests, among them were high-ranking personalities from politics and business, witnessed as Ilse Aigner, together with Chinese ambassador Shi Mingde and
KANGDE Chairman Zhong Yu, opened the technology center.
The European premiere of an entirely new automobile, the NIO EP9 (http://www.nio.io/), was also presented by KDX and NextEV (NIO).
The presented car is one of currently six vehicles worldwide.
The KDX Europe Composites R&D Center is an affiliated company of the KANGDE Group, a Chinese technology corporate group.
The partnerships include amongst others the TU Munich, Forward Engineering, KDX Roding Europe Automobile Design Center, OEMs, First-Tier suppliers and many more.
"COST DOWN APPROACH FOR COMPLEX STRUCTURAL PARTS"
The FIPCO Functional Integrated Plastic Components will take place for the seocnd time
21. and 22. June 2017 this year in Karlsruhe.
Georg Käsmeier, Managing Partner of Forward Engineering, will speak there on 22. June 2017 about cost down approach for complex structural parts using T-RTM technology.
FORWARD ENGINEERING WINS THE JEC WORLD 2017 INNOVATION AWARD
IN THE CATEGORY “AUTOMOTIVE STRUCTURAL”
The new development of a roof frame in T-RTM technology by Forward Engineering will now be honored with the JEC World 2017 Innovation Award!
The production of the roof frame was demonstrated for the first time during the K 2016 with live production in 2 minutes cycle time at the booth of Krauss Maffei.
The result is a cost-efficient roof structure, made of hybrid textiles in multi preform, functional resin areas and integrated metal inserts out of one tool.
The new Near-Net-Shape technology for shell-shaped components is a further highlight to minimize material-and process cost.
All in all the roof frame shows the next generation of innovative HP-RTM part design.
We would like to thank all project partners, who made a major contribution to the success of this project!
Partners: KraussMaffei (Germany), Alpex Technologies GmbH (Austria), Dieffenbacher (Germany), Saertex (Germany), Henkel (Germany), Handtmann (Germany), TUM/LCC (Germany)
Twelve innovations in different categories will be presented during the JEC Innovation Awards ceremony,
which will take place on Wednesday, March 15th 2017, 5p.m. at the JEC WORLD (Paris Nord Villepinte – France).
FORWARD DEVELOPS FUNCTIONAL-INTEGRATED AND
COST-EFFICIENT ROOF FRAME FOR K 2016
Forward Engineering demonstrates with a structural automotive application, produced in the resin transfer molding (T-RTM) process, solutions for a
cost-efficient and functional-integrated composite-lightweight-design. Due to the low viscosity of the used matrix material caprolactam, a quick infiltration
of the fibers and at the same time a high fiber-volume-content is achievable. The developed multi-preform-concept with a near-net-shape trim lowers the
material wastage of the expense fiber reinforcement and reduces the finishing to a trimming of a pure thermoplastic tear-off edge. High functional-integration and
a further reduction of post-treatment is achieved by process integrated metal-inserts. On the K 2016 in Düsseldorf (19. bis 26. Oktober, Halle 15, Stand B27/C24/C27/D24)
KraussMaffei will be demonstrating the production of the roof frame under series production conditions. Besides Forward Engineering the following partners were
involved in the development of the technology demonstrator: KraussMaffei (T-RTM-process, Reaction Process Machinery),
Alpex Technologies GmbH (T-RTM mold), Dieffenbacher (production of preforms/handling), Saertex (fiber layers), Henkel (bonding),
Handtmann (aluminum inlays), TUM / LCC (fiber selection).
MITSUI & CO. LTD., TOKYO, JAPAN,IS DOING AN
EQUITY PARTICIPATION IN FORWARD ENGINEERING GMBH (FE)
FE is a leading German design and engineering company specializing in automotive lightweight structures made from carbon fiber and other
composite materials. FE has an extensive track record in design and engineering activities relating to autobody and parts made from composite materials,
since the time it was part of Roding Automobile GmbH (spun off in March 2016), to reduce the weight of mass-produced vehicles. Mitsui will use
its global network and business activities to promote FE's automotive lightweight design and engineering services. It also aims to expand
its presence in the automotive carbon fiber market by leveraging FE's advanced knowledge and experiences relating to automotive
parts made from composite materials. Mitsui & Co., Ltd is one of the world's most diversified general trading and
investment companies that operates across 138 offices in 65 countries.
FORWARD ON THE
BEIJING MOTOR SHOW
The KDX Design Center and partner Kangde Composites KDC presented themselves at the leading
trade fair of the Chinese automotive industry. The unique combination of German engineering art
and chinese mass production raised great interest among Chinese automobile manufacturers.
When starting production at the beginning of 2017, Kangde Composites KDC will be a significant
participant in the global Tier 1 business for composite materials. Forward Engineering‘s Roding Roadster
demonstrated the broad range of possible applications of composite materials and
the adequate lightweight construction.
FORWARD IS FOUNDING THE
KDX RODING EUROPE AUTOMOBILE DESIGN GMBH
Forward Engineering and Beijing Kangde Xin Composite Material Co., Ltd (KDX) together have founded
the KDX Europe Automobile Design Center. The KDX Design Center develops the composite solutions
for the subsequent mass production at KDC in China. In this respect, KDX benefits from the
experience and competence of Forward Engineering. „German Engineering and favorable
Chinese Production“ is the slogan of this attractive offer to customers. Along with KDX‘s own
research center close to Munich, the customer benefits from cutting-edge engineering
and material and process know-how.