AZL – Aachen Center · Aachen Center for Integrative Lightweight Production – AZL 4 Equipment available at the RWTH-Institutes (selection) Mechanical testing (static, crash, fatigue)

AZL – Aachen Center for Integrative Lightweight Production

Prof. Dr. Christian Brecher

Prof. Dr. Christian Hopmann

Dr. Michael Emonts

Dr. Kai Fischer

Dr. Michael Effing

1Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de

New RWTH Aachen Campus2 areas with 800.000 m²

Emphasis on production technology: – 62 professorships– 11.350 students, 2.600 employees

RWTH Aachen is the European Center forProduction Technology

Area 1: Melaten

Area 2: West

RWTH Aachen260 research institutes

482 professorships

4.500 scientists

40.358 students

2 clusters of excellence:– “Integrative Production Technology for High-

Wage Countries” – “Tailor-made Fuels form Biomass”


Development of student numbers of Faculty ofMechanical Engineering at RWTH Aachen

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amtz

ahl S

tudi

eren

de

num

bern

ewen

scrip

tions

0

500

1000

1500

2000

2500

3000

0

2.000

4.000

6.000

8.000

10.000

12.00084

/85

85/8

686

/87

87/8

888

/89

89/9

090

/91

91/9

292

/93

93/9

494

/95

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696

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000

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202

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404

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606

/07

07/0

808

/09

09/1

010

/11

11/1

212

/13

13/1

411

.350

Gesamtanzahl Studierende (WS) incl. Wirtsch. Ing.

Anzahl Studierende 1. Semester (WS)2.680


Composite Competences along the Value Chain are present at the new RWTH Campus

Textiles (ITA)Plastics and Composites (IKV)Production Technology (WZL, IPT, ILT, ISF)Quality Assurance (WZL)Lightweight Design (ilb)Automotive (ika)

8 InstitutesMore than 750 scientistsMore than 1.100 student workers

Composite Competences and Cooperation since more than 25 years

1987 2014


Equipment available at the RWTH-Institutes (selection)

Mechanical testing (static, crash, fatigue)

Testing lab for fibres, textiles and preforms

Textile machines „from fibres to preforms“

Pultrusion- and filament winding equipment

RTM-systems, presses and autoclaves

Moulding machines for thermoplastic composites

Injection moulding machines

Prototype workshops

Machinery for manufacturing of pilot applications

Servo-hydraulic testing lab (incl. climate control)

Modular stiffness- and acoustic testing facilities

Impact testing

Crash facility for vehicle and component tests

Simulationhard and -software for simulation of complete vehicle models(u.a. 106 CPU Linux Cluster for managing confidential data:div. Solver, e.g. Abaqus explicit/implicit, LS-Dyna, ANSYS, PAMFORM, PAMCRASH and Fluent)


The AZL is designed as the Integrative Solution Provider

All required competences along the value chain are present at the new campusIntegrative and interdisciplinary approach along the value chain

All competences availableat the RWTH Aachen Campus

Industrial Partners

Material supplierManufacturing equipment supplier Molder Tier 1/2 OEM

∑ 750 scientists working on production technologies, lightweight materials and lightweight applications

Cooperation

Materials

Molder

Manuf. Equipm. Supplier

Tier 1 / 2

OEM


AZL – Addressed Branches and ProductsLight weight design for

Aerospace– Structural parts

Wind energy– Blades– Power train (gear housing, gear wheels , hollow shafts)– Nacelle and tower

Automotive industry– Bodywork– Structural parts– Power train (gear housing, shafts and gear wheels)

Transportation (Trucks, ships, trains, busses)– gear housing

(light weight design, reduction of noise emissions)– Structural parts

Sport and leisure industry– Sports equipment

Machine tools– Structural parts

(light weight design, stiffness, corrosion resistance)

Plant construction– Composite vessels and tubes

Chemical and food industry– Composite vessels and tubes


AZL Market and Technology StudyKick-Off Meeting with Participants

Start of project: March 2013, duration: 12 months

International industrial consortium with 34 companies– 15 Material Suppliers – 6 OEM – 7 Tier 1/ Tier 2 – 6 Equipment Provider

Kick-Off Meeting: Feb. 06th 2013in Aachen:


»Worldwide Market Study for Lightweight Applications«Current Status and Outlook

»Level 0« - MarketsDefinition of 5 target markets/ industries

»Level 1« - Market SegmentsDerivation of 47 market segmentsSelection of 13 attractive key segments based on pilotstudies (performed by Steering Comittee)

»Level 2« - Technology TreesDerivation of ~450 attractive components/ applications within the key segments

Pre-evaluation based on basic technology and marketcriteria, confirmed by expert interviewsSelection of 50 Highlight components

»Level 3« - Detailed Market Studies48 technology analyses including market size anddevelopment, technological maturity, competitors etc.

Selection of 12 Highlight components

»Level 4« - Business Cases12 detailed business cases including comprehensiveprofitability and technology analyses

Prioritization of components and enablingtechnologiesGoal of the 3. Report Meeting Workshop

- Task already accomplishedLevel 0Level 3 - Task still to be performed

Stag

e 2

Stag

e 1

Definition of relevant„trend markets“

Distribution into„segments“

Systematic searchbased on specificsearch parameters

Identification ofpotential enablers

Identification ofattractive

applications

Structuring ofMarkets/ technology

fields

Derivation based on current or expectedcapabilities

Systematic approach:

Definition ofstudy scope

Stag

e 3


Exemplary ProceedingStage 1 – Pilot Study

Market SegmentationStructured overview on market segments, structureand overall market volume

Segment AnalysisOverview on high level chances, risks

Technology and market trends

Segement Evaluation High level aggregation of market and technologyintelligence

Selection of most promising segments based on expert knowledge (interviews) and appraisal of thesteering committee

2 31


Exemplary ProceedingStage 1 – Pilot Study

Segment Sub-structureOverview on technology fields within the marketsegment at hand

Detailed Segment AnalysisDerivation of major challenges within these sub-segments in order to enable a focussed selectionof growing or developing marketsegments

»Technology Tree«Market requirement-based breakdown of relevant sub-segments into systems and components

Criteria-based selection of applications/ components (advantages during product usage, advantagesfor production, subjective »product experience«)

2 31


Exemplary ProceedingStage 2 – Detailed Analysis

Value-Chain Overviewconnected and/or synergetic technologies withinthe value-chain of the component at hand

Visualization and quantification of added valuesteps

48 Detailed Technology and Market AnalysesDetailed Aggregation of relevant technology- andmarket-related information

Executive Summary for quick evaluation

2 31


Exemplary ProceedingStage 3 – Business Cases

Application/ Component SelectionCriteria-based portfolio analysis of remainingapplications and components

Final selection of 12 most promising highlightapplications

12 Business Case AnalysesHighly detailed calculation of business cases for theselected highlight applications/ components

Derivation of relevant required technologies, materialsand/or services to address these highlights

Selection of most attractive components for furtherconsortial projects and implementation

2 31


Integrative Production Technology and Material Science

Multi-Material-SystemsAutomation of Lightweight ProductionLight weight and recycling suited product development, manufacture, assembly, planning and quality assuranceMore efficient methods for processing, machining, assembly and recycling

Holistic consideration of light weight design operationsServices across branches, products and materials

Integrative Approach

Growing Industrial Demand

Production pre-

arrangements ManufactureAssembly/handling

Product development

Advance development Operation

Disassembly/

recycling

Production systems Plastics

Metals

Process technologies

Production and recycling managementProduction quality

FRP

FRP Composites

Business quality


Cluster „Integrative Production Technology“ (Home of AZL)

Pic

ture

s: C

apric

orn

Dev

elop

men

t, H

enn

Arc

hite

kten

New Building complex of the new Cluster “Integrative Production Technology” at RWTH Aachen University:

25.000 m² Machinery Hall and Office Buildingsfor AZL, WBA and E-Lab

Infrastructure for additional 800 Scientists

3.000 m² for shops, gastronomy, service


Cluster „Integrative Production Technology“ Home of AZL – Impressions

Source: Capricorn Development, Henn Architekten

25.000 m² Machinery Hall and Office Buildings for AZL, WBA and E-Lab

Infrastructure for additional 800 Scientists


New AZL Equipment (Examples) in Addition tothe Existing Equipment of the Partner Institutes

Composite Press System– Table Size: 1,8 m x 2,8 m– Tonnage: 1.800 to

Handling Systems– Loading of press system– Handling of semi-finished

products– Handling and processing of parts– Integrated quality assurance

systems

Large-Scale ProductionSystems for– Injection molding– Compression molding– Thermoforming– Combined processing

15 m

6 m

Multifunctional Composite Press

Handling System(Process Preparation)

Handling System(Part Handling, Finishing)


AZL Infrastructure and Services

AZL Development Centercompletion in 2014

Office building

Machinery hall

Staffing: – Scientists– Technicians– Designers

Founded in 2012

Full Scale Production Equipment for:Thermoplastic systemsThermoset systemsMultimaterial systems

Composite AcademyEducation for industrial staff– Technicians, lab workers, engineers, managersSeminarsSales and Marketing Excellence

Consultancy ServicesMarket studiesTechnology transferBenchmarkingInnovation management

S E

R V

I C

E S


Production management

Produktions-vorbereitung Fertigung Montage/

HandhabungProdukt-

entwicklungVor-

entwicklung BetriebDe-

Montage/Recycling

Produktions-vorbereitung Fertigung Montage/

HandhabungProdukt-

entwicklungVor-

entwicklung BetriebDe-Montage/

Recycling

production -pre-arrangements

manufacture assembly/handling

product -development

pre development operation disassembly/

recycling

Integrative Strategic Research Topics

Efficient recycling processes

Production management for light weight components

Monitoring and optimization of quality

More efficient production systems and processes, new joining methods

New composites (organic, non-organic) and light weight structures

Design and simulation tools for light weight components


Campus Melaten of RWTH Aachen University –Next location for your development site?

+5 anonymous


Campus Project of RWTH - One of the largestEuropean research landscapes


Campus Project of RWTH - One of the largestEuropean research landscapes


Contact for further Information

Dr. Michael EmontsCEO AZL RWTH,Managing Director AZL Aachen GmbH

Tel.: +49 241/ 8904-150

Email: [email protected]

Dr. Kai FischerDivisional Director AZL RWTH: Production Technology Composites,Managing Director AZL Aachen GmbH

Tel.: +49 241/ 80-23884


Dr. Michael EffingSenior Advisor AZL Aachen GmbH

Tel.: +49 241/ 80-23887


Partner Model of AZL Aachen GmbH

Introduction of Services and Partner Model in the Field of Lightweight Production

Dr. Michael Emonts

Dr. Kai Fischer

Dr. Michael Effing

24AZL Aachen GmbH – Excellence in Lightweight Production

Partner of AZL –Excellence in Lightweight Production

Mission of AZL Aachen GmbH:

■ Industrial R&D-services in cooperationwith research institutes

■ Workshops and seminars forindustrial employees

■ Networking: Lightweight activities ofresearch institutes, associations andcompanies

■ Support of RWTH research instituteswith invest, infrastructure, services

Be part of the AZL Aachen Network

Exclusive Partner Labels:

Mission of AZL RWTH:

■ Research

− Production technology for themass production of lightweightcomponents

− Process chains for the massproduction of composite-basedmulti-material systems

■ Education



Partnership

Status Usage of label „OFFICIAL / FOUNDING*PARTNER“ for your public relations

Definition and discussion of pre-competitive projects and cooperations

Discussion of strategies of AZL

Lightweight activities of RWTH Aachen research institutes, associations and companies

Networking with other industrial Partners of AZL Aachen GmbH

Research consulting/ project definition

Setup of consortia for industrial research projects and for joint research projects with public funding

Identification of public fundings for individual research demands

-

Annual Partner Meeting

Networking

Initialization andCoordination ofResearch Projects

Additional Marketing

Usage of label „PREMIUM PARTNER“ for your public relations

Definition and discussion of pre-competitive projects and cooperations

Discussion of strategies of AZL

Lightweight activities of RWTH Aachen research institutes, associations and companies

Networking with other industrial Partners of AZL Aachen GmbH

Research consulting/ project definition

Setup of consortia for industrial research projects and for joint research projects with public funding

Identification of public fundings for individual research demands

Extended public relations (Internet, Publications, Presentations, etc.)



Public Relations

Usage of exclusivepartner label

Usage of label „OFFICIAL PARTNER“ for your public relations like letter paper, website, presentations, print media, etc.

Listing as “OFFICIAL Partner” with company logo and explanation of portfolio to acquire new customers and development partners (max. 700 digits)

Listing of your company in the showcase of AZL Aachen GmbH as “OFFICIAL Partner” with company logo and trade name in the building of the new Cluster “Integrative Production Technology

Setup of publications, presentations, newsletter, partner meeting related to your innovative products

Listing on the website

Listing in the showcase

Usage of PR activities



Public Relations











Public Relations









Composites Europe 2013, Stuttgart



Human Resources Marketing

Contact to junioremployees

Highly qualified staff is educated within lectures and practical research at RWTH Aachen within the field of materials science and lightweight production

Publication of jobs for internships and employment

Direct contact via employees of AZL Aachen

Placement of job offers viaWebsitePrint media

Comfortable recruiting section for specialists (technicians, student workers, graduates)

3 months duration after publishing

Printed job offers are published in the showcase withinin the building of the new Cluster “Integrative Production Technology”

Usage of different media

Recruting section of AZL Aachen website

Publishing in Showcase



Industrial R&D Consulting

Setup of consortia forjoint research projects

Identification of potential partnersIndustrial companiesResearch Institutions

Consulting on focusing research topics

Consulting how to use AZL infrastructure as technology platform

Risk-reduction by identification of available public funding possibilities for your demand

BMBF, BMWI, EU, Cross-Border Fundings, etc.

Usage of the expertise of AZL Aachen to focus research topics

Direct contact via the AZL Aachen network partners to setup consortia for public funded projects

Possibility to use AZL infrastructure as technology platform for

Identification of publicfundings



Industrial R&D Consulting

WorkshopsFree participation in workshops to define cost-shared pre-competitive projects

Thermoplastic Tapes - Material and Processing Benchmark (May 15th 2014)

New Designs for Low-Cost and Energy-Efficient Double-Belt Presses for Continuous Composite Manufacturing (May 15th 2014)

High-speed RTM matrices (May 27th 2014)

Back-moulding of thermoplastic tailored preforms (June 05th 2014)

Scheduled after annual partner meeting 2014:Quality control and -management for highly integrated process chains

Individualized production for high-volume markets



Face-to-Face Networking

Annual Partner Meeting Platform to initialize projects within the network of AZL Aachen partners

Pre-competitive R&D projectsCooperation

Presentation of innovative R&D projects

Discussion of the AZL Aachen strategy, update on new equipment and services

Strengthen the network between AZL Aachen partners and the lightweight activities of the RWTH Campus

Dates:July 03 2014July 02 2015

Participation of 3 employees included


Campus Melaten of RWTH Aachen University – Next location for your development site?

+5 anonymous



Contributions for a 2-year-partnership (2014, 2015) Number of Employees

< 2525 - 250250 - 500

> 500

*Annual contribution with commitment for a 2 year partnership (2014, 2015)

Anual Contribution*

2.000,- €5.000,- €7.500,- €

10.000,- €

Anual Contribution*

25.000,- €


Contact for further Information

Dr. Michael EmontsCEO AZL RWTH,Managing Director AZL Aachen GmbH

Tel.: +49 241/ 8904-150


Dr. Kai FischerDivisional Director AZL RWTH: Production Technology Composites,Managing Director AZL Aachen GmbH

Tel.: +49 241/ 80-23884


Dr. Michael EffingSenior Advisor AZL Aachen GmbH

Tel.: +49 241/ 80-23887


Documents

AZL – Aachen Center · Aachen Center for Integrative Lightweight Production – AZL 4 Equipment available at the RWTH-Institutes (selection) Mechanical testing (static, crash, fatigue)