References from the automotive industry

For shell constructions, drive trains and chassis, fibre composite materials pave the way for technical and economic advantages over metallic constructions. Combined with drastic increases in the cost of raw materials, legally required reductions in exhaust emissions, shorter model cycle periods and increasing demand for niche vehicles, construction with fibre composite materials presents a sensible alternative to lightweight metal concepts.


    • Development and series production of the external side frame for the BMW i8 Roadster
      BMW has the worldwide technology leadership for the production of CFRP components and use in vehicles; accompanied by the highest demands on production technology and quality. We are therefore very proud that BMW has nominated us to produce the side frames left / right for the i8 electric sports car. The series start was in the first quarter of 2018, approx. 2.600 sets are manufactured per year at ACE.



    • Audi AG
      Development and series manufacturing of the MSS Tunnel and the B-pillar for the models Lamborghini Huracan and the new R8 Spyder (coupe´+ spyder)

      ACE was nominated by Audi to develop and manufacture crash relevant CFRP parts for the new car body “MSS”. Internaly we call the parts MSS tunnel and the associated crash-cover. The tunnel is manufactured by the RTM process, the crash-cover by the carbon SMS process. Depending on the tunnel variant there are up to 25 studs be applied in a full automatic Tucker method. In addition to these components, ACE is going to manufacture the B-pillar (outside) of the R8 successor. This part will be produced by the RTM process as well. The annual production rate is for approx. 1.200 Huracan and 2.000 R8 per year (each, coupe and spyder). If necessary, the production rate can be extended.



    • AMG / Daimler AG
      Development and production of the spare tire well for the Mercedes AMG S63 and S65 models

      For AMG, the factory tuner of Damiler, ACE has developed a spare wheel compartment for the S63 and S65 models . The "Emulde" is a single-shell part with a sandwichcore. It is produced by the RTM process. The production is designed up to around 4.000 parts per year.



    • Automobili Lamborghini Spa
      Development and production of CFRP components at the rear of the Aventador Spyder

      ACE has developed seven different components at the rear of the Aventador Spyder in a class A surface. It involves the engine bonnet with cover, the bonnet frame and the side flaps and fender covers (left + right). All components are made by the RTM process . The production is designed to around 1.000 parts per year.



    • Volkswagen AG
      Development and series production of CFRP components for the "one -liter car " VW XL1

      The VW XL1 is the " one-liter car " of the Volkswagen AG. As of 2002, Volkswagen was working on the concept and began with the production in March 2014. ACE was charged with developing and prototyping of the rear fender in a class A surface. Due to the undercuts a complex RTM tool was made with sliders. For the development of the fender Volkswagen and ACE were awarded with the 1st prize at the SPE Innovation Award 2012 . In the further course of collaboration ACE got the order to produce base plates in a small series of 250 pieces.



    • Development and series production
      of CFRP components for the rear of the Aventador

      For the Aventador, the successor to the Murcielago, ACE manufactures the bonnet panels, side flaps, cover fenders and engine bonnet from CFRP. These lightweight components are produced using the RTM process and lead to overall weight savings of approx. 30 %. The series production process is designed for approx. 1,000 sets per annum.



    • Daimler AG
      Series production of the CFRP inner shell for the SL AMG

       

      ACE worked together with Daimler AG to develop the design of the inner shell of the SL AMG's engine bonnet in CFRP. Here, the partial carbon styling is required to meet special requirements. ACE manufactures the series for Daimler AG, producing up to 30 units per day.

       



    • Audi AG
      Development and series manufacture of the CFRP engine bonnet and the side panels for the R8 Spyder

      In cooperation with Audi AG, ACE developed the soft-top compartment cover and the side panels (fenders) for the Audi R8 Spyder, built using CFRP. Today, ACE manufactures these components for the R8 Spyder using the RTM process and is also responsible for paintwork and assembly as a system supplier.



    • Automobili Lamborghini Spa
      Development and series production of the Gallardo Spyder's CFRP tailgate


      In cooperation with Lamborghini and Audi AG, ACE developed a tailgate made of carbon fibre (CFRP) with Resin Transfer Moulding (RTM) production technology, bringing the tailgate to series production in late 2005. The company faced a particular challenge here in terms of manufacturing: meeting the stringent requirements of Class A surface quality while also achieving strongly contoured surfaces, including, among others, the typical Lamborghini slats. Thanks to the CFRP construction, a design could be realized that would not be possible using a metal structure, and a 30% weight saving was achieved. Approx. 1,500 tailgates are manufactured per year at ACE



    • Bugatti Automobiles S.A.S.
      Development and series production
      of the CFRP side panels for the Bugatti Veyron


      ACE was involved in various development aspects of the composites for the Bugatti Veyron, the 1,001 PS "street-legal racing car". The CFRP exterior skin parts (side panels) are now in series production. The utmost value is placed on the surface quality of the components for this highly exclusive vehicle.



    • Porsche AG
      Development and series production of
      CFRP parts for the Porsche Carrera GT


      During the development phase for the Porsche Carrera GT, ACE was a firm development partner with a focus on lightweight construction and acted as a specialist in fibre composite materials. As a development partner, we supported the Porsche development team in the fields of design, dimensioning and material selection and qualification. In preparation for production, we supported Porsche in developing the tool concept and then carried out series production of a total of 6,000 carbon fibre stiffener elements.

       



    • Hymer AG
      Development of lightweight construction concepts for mobile homes

      Within the framework of a development contract, we investigated the use of FRP construction for the front section of a Hymer mobile home.



    • Liebherr GmbH
      Composite developments for Liebherr mobile cranes

      Weight reduction is also growing in significance in the heavy goods vehicle sector. In the commercial vehicles sector, ACE therefore worked in cooperation with Liebherr to develop a complete composite crane cabin and cabin doors, as well as manufacturing prototypes. RTM technology was once again used as the manufacturing process here.

       


As well as the reference projects mentioned here, many of our engineers also have further development experience in automotive construction from projects at EADS-Dornier.


    • Unimog UX 100 and U200/300 with CFRP cabin
      using RTM construction


      The FRP cabin of the Unimog UX 100 and U200/300 represents a new development in the field of automotive construction. Weighing just 70 kg, the bodyshell structure of the UX 100 consisted of only eight components, manufactured using the RTM process and then glued together to form the structure. This construction allowed the cabin to satisfy all relevant regulations (EEC, ECE-R29) and tests (impact testing, etc.). The CFRP cabin entered series production at 1,000 cabins per annum (UX 100). The bodyshell structure of the Unimog consisted of only nine components with a total weight of around 150 kg. The CFRP cabin entered series production at around 2,500 cabins per annum.



    • Development and construction of prototypes of a CFRP hardtop for the Mercedes SL

      Following construction of a hardtop prototype for the Mercedes SL, the development of the RTM production concept was designed for a quantity of 13,000 units per annum. At 10 kg, the entire structure of the hardtop was around 30% lighter than an equivalent aluminium construction and, following a standard painting process, satisfied the requirements of Class A surfaces. Furthermore, Cardan shafts made of CFRP were developed for the SL; these were manufactured using multiple-coil winding processes and tested. The flange connection was realized using cost-effective injection-moulding technology.

       




ACE Advanced Composite Engineering GmbH
In Oberwiesen 18, 88682 Salem-Neufrach, Germany  I  Tel: +49 7553-5908-0  I   E-Mail info@ace-composite.com