Additive Manufacturing and Bio-Materials in Automotive Industry in a Skill Development Programme with case studies

1. Skill Development Programme (SDP) on
“Recent Advancements in Materials and Digital Manufacturing”
5th to 9th October 2021 at SGT University, Gurgaon
ADDITIVE MANUFACTURING AND BIO MATERIALS IN
AUTOMOTIVE INDUSTRY
Dr. Rohit Singh Lather, Ph.D.
Email: rohitsinghlather@gmail.com ; Mobile: 9899960797
Mechanical Engineering Department
The NorthCap University, Sector – 23 A, Gurugram

2. Dr. ROHIT SINGH LATHER
Dr. Rohit Singh Lather
Associate Professor and Head, ME Department
The NorthCap University.
B.Tech. (ME) from Kurukshetra University.
M.Tech. Automotive Engineering from Vellore Institute of Technology (VIT) and
the Automotive Research Association of India (ARAI) in 2008.
Ph.D. Energy Studies from the Indian Institute of Technology Delhi (IIT Delhi)

3. PRESENTATION OUTLINE
• Introduction to Automotive Industry
• Introduction to Materials in Automotive Industry
• Green House Gasses & Sustainability in Automotive Industry
• Innovative Manufacturing in Automotive Industry
• 3D Printing
• Bio-Material in Automotive Industry

4. AUTOMOTIVE INDUSTRY 2017 - 2030
Source: Global automotive market size 2030 | Statista
It is projected that the global automotive industry will grow to just
under nine trillion U.S. dollars by 2030.

5. MATERIALS FAMILY
There are over 50,000 engineering material available in the world today.
Source: Ashby M. F. Materials Selection in Mechanical Design.Elsevier.2011

6. MATERIALS PROPERTIES SELECTION
Six Set of Important Properties
• Price and availability
• Density, Modulus, Damping, Yield Strength, Tensile Strength, Hardness, Fracture Toughness, Fatigue
Strength, Thermal Fatigue resistance, Creep Strength.
• Functional requirement corresponding to the performance index in view of the material properties.
• Thermal, Optical, Magnetic and Electrical properties
• Oxidation, corrosion, friction, abrasion and wear
• Ease of manufacturing, joining, etc.
• Appearance, texture, feel etc.

7. MATERIALS IN AUTOMOTIVE INDUSTRY
Automotive manufacturing requires a high volume of materials.
28000 - 30000
Parts are assembled with different raw
Materials

8. AUTOMOTIVE MATERIALS IN A CAR BY 2025
Source: Statista 2021 Source: Ashby M. F., Johnson K. Materials and Design. Elsevier. 2014

9. AUTOMOTIVE MATERIALS ENERGY INTENSITY
Source: Ashby M. F., Johnson K. Materials and Design. Elsevier. 2014

10. AUTOMOTIVE MATERIALS IN A CAR BY 2025
Source: Statista 2021

11. AUTOMOTIVE MATERIALS IN A CAR BY 2025
Metals Composites Plastics Elastomer
• High Strength
Steel
• Aluminium
• Magnesium &
Titanium
• CFRP
• GFRP
• NFRP
• Other Composites
• PC
• ABS
• PA
• PP
• PU
• Others
• EPDM
• NR
• SBR
• Others
Source: Automotive-lightweight-materials-market. Market-Reports.www.marketsandmarkets.com.2020

13. Aluminium is an important staple of the automotive industry when it comes to lightweight design, but it is more energy-
intensive to produce than steel. To address this issue, Audi is currently testing an innovative recycling concept designed to
conserve resources.

14. AUTOMOTIVE INDUSTRY & GREEN HOUSE GASSES
Chronological development of the predetermined legal CO2 fleet limits in
the markets of USA, European Union, Japan and Canada
Canada
European Union
United States
Japan
220
200
280
160
140
120
100
80
CO
2
[g/km]
2008 2010 2012 2014 2016 2018 2020 2022 2024 2025
20g CO2/km for 2050 – A target suggested by some countries

15. AUTOMOTIVE INDUSTRY & SUSTANABILITY
62%
Automotive
organizations
sustainability
strategy
$50 billion
investment to meet
sustainability commitments.
74%
OEMs have
electric vehicle
plans
52%
Organizations
Supporting and
promoting circular
economy
The automotive industry in the era of sustainability – Capgemini India
86%
In France, 86% of
end-of-life
components by
weight is saved and
recycled owing to
the circular economy

16. BMW 10 POINT SUSTANABILITY
The automotive industry in the era of sustainability – Capgemini India

17. DOUBLING TIME
In what duration does a quantity double?
• Period of time for a quantity to double in size or volume.
• When the relative growth rate is constant, the quantity undergoes exponential growth and has a
doubling time.
• Applied to population growth, inflation, resource extraction, consumption of goods, compound interest,
volume if malignant tumors, etc.
• For a constant growth rate of r%, the formula for doubling time Td is given by
• Steel consumption is doubling every 20 years
• Aluminum consumption is doubling every 9 years
• Polymers in every 4 years
!" =
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18. ECO - EFFICIENCY
• Merges ecological and economic goals
• Improve productivity of energy and material inputs
to reduce resource consumption and reduce
pollution per unit of output.
• A win-win approach that benefits both the bottom
line and the environment.
Seven Dimensions
1. Reduce material intensity of goods and services.
2. Reduce the energy intensity of goods and services.
3. Reduce toxic dispersion.
4. Enhance material recyclability.
5. Maximize sustainable use of renewable resources.
6. Extend product durability.
7. Increase the service intensity of goods and services

19. INNOVATIVE MANUFACTURING PROCESSES
REDEFINING AUTOMOTIVE INDUSTRY
• Manufacturing is moving from Industry 2.0 to 3.0
• Manufacturing sector is focusing on Industry 5.0 even before the full
potential of Industry 4.0 has been realized.
• Additive manufacturing is a disruptive and rapidly-growing
technology
• Allows quick or rapid prototypes
• Complex designs, which otherwise would not have been possible
• AM is used for Testing, Manufacturing, and Assembling automotive
parts and components with higher efficiency, optimization, and cost-
efficiency.
Source: Cotteleer M., Joyce J. D opportunity: Additive manufacturing paths to performance, innovation, and growth. Deloitte Review. 2014.

20. Source: Cotteleer M., Joyce J. D opportunity: Additive manufacturing paths to performance, innovation, and growth. Deloitte Review. 2014.
• BMW claims that the company had recognized the technology 28 years ago.
• BMW has an Additive Manufacturing Center in Munich
• 100,000 precision components are developed and manufactured each year.
• components like prototypes to small plastic mountings and highly-complex metal chassis parts.
• Volkswagen (VW) established an additive manufacturing center in 2018.
• 3D printing for prototypes and tool production, with a target of introducing additive manufacturing over the next
few years for end-use production of parts.
• 100,000 3D target to print parts per year
• “Automotive Application of the Year” award in 2018. for demonstrated savings using 3D printing
• 3D printing to the light-weighting of components in production vehicles, including water connectors for the
inside of the Audi W12 engine.

21. • For the automotive industry, Additive Manufacturing
has opened doors for
• Newer designs
• Cleaner, lighter, and safer products
• Shorter lead times
• Lower costs.
Source: Cotteleer M., Joyce J. D opportunity: Additive manufacturing paths to performance, innovation, and growth. Deloitte Review. 2014.

22. Source: Additive Manufacturing in the Automotive Industry - FutureBridge

23. 3D Printing: opportunity to
develop prototypes and full-
scale parts that are
significantly more complex
than possible when forming or
molding. Parts can be printed
with a variety of mediums
from high-strength plastics,
aluminium and metals.
Source: Next-Generation Automotive Manufacturing Materials and Processes - StartUp HERE Toronto.2018

24. PLASTIC AUTOMOTIVE PARTS
Source: New trends in plastics consumption in the Automotive Industry – Which materials will be the winners .2020
30,000 parts in a vehicle
1/3 are made of plastic
39 different types of plastics and polymers
70%+ of the plastic used in automobiles
comes from four polymers: polypropylene,
polyurethane, polyamides and PVC.
Plastics and composites are reshaping car design

25. 3D METAL PRINTING
Source: Nicholas R M. How does the automotive industry benefit from 3D metal printing? . Metal Powder Report.2019. https://doi.org/10.1016/j.mprp.2019.07.002
Printing and prototyping • 3D metal printing allows engineers to create a fully functional prototype
directly from their digital design without the additional fabrication steps that
normally fall in the middle.
Replacing rare spare parts • Generating spare parts for rare and limited-run vehicles — or any vehicle
that owners or shops might have trouble getting their hands on.
Lighter cars and higher fuel
efficiencies
• Reduce the weight of many automotive components between 40 and 80%.
Bespoke car designs • Drivers can choose things like interior and exterior colours and add-ons, but
the make, model and look of the vehicle are the same as every other one of
that particular model on the road.
3D Printing Full Vehicle • XEV Hong- Kong-based automotive company has 3D printed LSEV, electric
vehicle

26. Source: 3D opportunity in the automotive industry Additive manufacturing hits the road. Deloitte University Press

27. Source: Stratasys. Five Ways 3d Printing Is Transforming The Automotive Industry.2020
FROM SMALL TO BIG: FLEXIBLE, OPTIMIZED DESIGN
Start Small And Scale Up Rapidly
RAPID TOOLING WITH ADDITIVE MANUFACTURING CUTS
THE STEPS, CUTS THE TIME
Produce pre-series moulds produced with a 3D printer and then do
the first 50 to 200 design iterations for the tooling
FAST CUSTOMIZATION VIA 3D PRINTING
Economical solution to carmakers looking to provide an
array of trims and options for consumers.
VALIDATION AND ADVANCED MEASUREMENT ON DEMAND
Time saving in process real time measurements
REAL WORLD FUNCTIONAL TESTING
Real application for producing automotive components

28. Source: Stratasys. Five Ways 3d Printing Is Transforming The Automotive Industry .
ULTEMTM 9085 resin: A flame-retardant, high-performance
thermoplastic, is the go-to material for complex parts that go in the
test vehicles, including inside engine compartments.
• The weight-to-performance ratio is similar to some
aluminium alloys used in these applications, and
• Temperatures resistant up to 186 deg. Celsius.
ULTEM 1010 resin, which has higher resistance to temperature
than ULTEM 9085 resin, as well as increased rigidity, and can
withstand temperatures as high as 214 deg. Celsius.

29. Source: Real Examples of 3D Printing in the Automotive Industry
DUCTS AND BRACKETS
GEAR LEVER AND PEDALS
DISK BRAKE ROTOR

30. Source: Real Examples of 3D Printing in the Automotive Industry
Porsche’s 3D-printed custom seats
3D printing for automotive brackets
Ford 3D prints parts for high-performance Mustang Shelby GT500
Volkswagen Autoeuropa: 3D-printed manufacturing tools
3D-printed lug nuts that save car wheels from thieves
Greater customisation with 3D printing
Chasing victory: 3D printing for motorsports

31. Source: Nicholas R M. How does the automotive industry benefit from 3D metal printing? . Metal Powder Report.2019. https://doi.org/10.1016/j.mprp.2019.07.002
XEV LSEV 3D printed electric
vehicle
• It can be printed in about three days
• The interior and exterior are 3D printed
• like seats, brakes and lights still have to
be installed manually.
• Range is 90-mile and a top speed of 43
miles per hour

32. FACTORS FOR TRANSITION FROM CONVENTIONAL
MATERIALS TO BIO MATERIALS
Identifying and selecting a bio-based materials to replace conventional non-renewable materials in
the automotive industry, the following four criteria must be met in addition to the environmental
benefits at the OEM end:
1. Cost
2. Material properties
3. Production methodology
4. Continuous supply.

33. DRIVERS FOR BIO-MATERIALS IN AUTOMOTIVE
INDUSTRY
• Sustainable Development - Sustainable raw material
• Environment – by-product; CO2 reduction;
• reduced petroleum
• Social – Local agri-economy
• Weight reduction – Fuel economy – lower CO2
• Cost equivalent or reduction
• Reduced processing energies
• Production gains
• Increased design flexibility

34. • Global automotive consumption of carbon fibre composites is
increasing – and growth rates show no signs of slowing down any time
soon.
• Carbon fiber projected to reach 9,800 metric tons by the year 2030.
• Corporate Average Fuel Efficiency (CAFE) standards and pollution
emission objectives require automakers to increase kilometres per
litres
• Light-weighting an automobile is one of the best ways to achieve high
fuel economy and lower emissions.
• Car “road loads” must be reduced by about 30% to meet these
standards
• A reduction of 25-70% car body-weight reduction possible with the
use of carbon fibre
Source: Oliver M G. Plastics and composites are reshaping car design, IHS report shows. American Chemistry Council. 2014

35. BIOMATERIALS IN AUTOMOTIVE INDUSTRY
• In efforts to reduce CO2 emissions over the entire vehicle life cycle, sustainable and renewable raw
materials like flax, hemp, cellulose, cotton and kenaf are being used for automotive components. –
Volkswagen Group
• Applications of biomaterials include door trims, armrests, floor insulation, trunk linings, door and side
panel trim and hood insulation.
• 2006 - first engineering-grade biopolymers - DuPont Performance Polymers
• expand its portfolio of sustainable, bio-based materials where it is technically feasible and
economically sustainable.
• Using a locally sourced product, bio-degradable, it can reduce carbon emissions, due to lower
consumption petroleum-based materials.

36. • Bio-source fibres are less dense than traditional fibres (such as glass), thus are components made of
them are lighter than conventional ones.
• Bio-composite materials tend to absorb the impact energy, as opposed to composite materials based on
mineral fibres, which tend to break, making them safer for the occupants of the vehicle in case of an
accident.
• Wood, cotton, textile and leather seats there are two main uses: as reinforcement fibres or filling, or to
create polymers.
• Flax and hemp - Used in the interior door panels, back set shell, armrests and floor panels.
• Coconut fibres and bio-foams - Used for making seats, headrests and headrest.
• Cotton and other natural fibres – Provide superior soundproofing properties and are used in interior
components.

37. • Bio-based composites are reinforced or filled with natural fibres, including bast fibres, originating from
the stem of plants (such as hemp, flax and jute).
• Bio-polymers can be obtained from a variety of sources, including soybean, castor oil plant, corn or
sugar cane.
• Raw materials are, usually, fermented and go through a series of conversions to produce polymers
that can be used in plastic composites.
• Just like conventional polymers, bio-polymers can be extruded, moulded, injected, expanded or
thermoformed.
• Composite materials based on bio-degradable sources generally are used in two ways: as a
replacement for petroleum-based polymer or as a replacement for synthetic fibres (such as glass
fibres).

38. HISTORICAL BACKGROUND OF BIOMATERIALS IN
AUTOMOTIVE INDUSTRY
1930’s • Soy bean oil for paint - Ford
1982 • Wood flour filled door panels - FIAT
1999 • Introduced kenaf fibres as natural reinforcing fibres in PP/kenaf resin - Toyota
2003-04 • Interior trims with of 30-40% wood fibres - FIAT
• PLA spare tire cover - Toyota
2006 • Bio-fabric made of bio- PTT, which replaced 1,3-propandial with a corn based
substitute. - Toyota
2008 • Soybean oil based polyol PUF - Ford
Source: Tseng S. Using bio-based materials in the automotive industry. 2013

39. 2009 • PLA/PPA /Hybrid resin of Ingeo and PP mix for interior trims - Hyundai
2010 • Bio-fabric for seat, roof boot lining, carpet - Honda
• PLA/PP hybrid resin for interior trims - Toyota
• Coconut – interior and exterior trims - FIAT
• Storage bin and door panels - Ford
2011 • Soybean based bio PUF head restraints - Ford
• Ecological Plastic, sugar cane based bio-PET - interior carpet and seat trim - Toyota
• Renewable nylon fuel lines made from castor oil - FIAT
• Flax, sisal – door panels, linings - BMW
• Kenaf fibres – headlining, interiors insulations - GM
2012 • Cotton bamboo – Interior trims - Mitsubishi
Source: Tseng S. Using bio-based materials in the automotive industry. 2013

40. BIO-MATERIALS AUTOMOTIVE INDUSTRY
• Renewable oils in partial substitution of petroleum for foams
– soy oil based urethanes and foam
– castor oil based foam
• Renewable fibres and fillers in plastic composites
– reinforcements: wheat straw, hemp, cellulose, coconut coir
– fillers: soy hulls, soy flour, coconut shell powder
– impact modifiers: TKS, guayule
• Renewably sourced thermoplastic resins
– bio-polymers: PLA, Sorona (PTT), etc.
– bio-based chemicals: PE, PP, PET, etc

41. AUTOMOTIVE REQUIRMENTS FOR MATERIALS
• Harsh operating environments
– temperatures from -30 °C to 85 °C; 90%+ RH for interiors
– temperatures from -30 °C to 150+ °C under hood – dent/ding mar resistance for exteriors
• Long product lifetime (10 to 15 years)
• Large volumes (Over 1,00,000)
• Fast cycle times
• Mass customization
• Reliability and durability

42. • Kenaf - Tropical plant belonging to the mallow family.
• Its cane-like stems grow to a height of four meters,
• the fine fibres that are extracted from them go to produce the door trim of the current Golf

43. Source: Tseng S. Using bio-based materials in the automotive industry. 2013
BIOMATERIALS IN AUTOMOBILES
Biomaterials in a typical car
Biomaterials in a Volkswagen Polo

44. Biomaterials used by Mercedes Benz
Soy based products used by Ford in vehicles
Door panel made of hemp fibres and epoxy resin
Source: European Industrial Hemp Association, Hemp Fibres for Green Products
Source: Tseng S. Using bio-based materials in the automotive industry. 2013

46. makes car parts from used coffee beans
• 62 million+ pounds of McDonald's coffee chaff go straight to landfills.
• McDonald's partnered with Ford Motor Company to help minimize their
waste to landfills.
• Ford research team finds that coffee chaff (unused dried skin that comes
off the bean during the roasting process) can be used to make car parts
that need to withstand high temperatures, like headlights and car battery
covers.
Source: How Ford makes car parts from used McDonald's coffee beans | Business Insider India
Image Source: Plastic News
Coffee Chaff
Heated to high temperatures
Mixed with plastic and other additives
Material that can
be formed into
various shapes.
Coffee-bean skins into
sustainable headlights

47. • Headlights were made up of plastic and talc, a mineral that has to be mined.
• The coffee chaff replaces some of the talc, making the car part 20% lighter.
• Molding the coffee chaff also uses 25% less energy than the previous material combination.
• The chaff component meets all durability and performance requirements, and it can withstand high
temperatures much better than talc.
• Manufactured using injection molding.
• Pellets made from plastic and chaff are combined in the machine.
• The material is heated and mixed, then shot into a mold and placed under pressure that forms the
shape of the part.
• Each headlight takes 30 to 60 seconds to form.
Source: How Ford makes car parts from used McDonald's coffee beans | Business Insider India