New Materials and Manufturing for Product Life-Cycle Sustainability Edoardo RABINO Centro Ricerche Fiat FoF Ad hoc Industrial Advisory Group Nov 30 th, 2009 1
New Materials and Manufturing Key ftors for future competitiveness Key ftors Light, smart, green: the application of light and smart materials is a key element for further improvement in efficiency and lower energy consumption. From Knowledge to Value: ICT technologies will support product and process optimisation along the whole supply chain while increasing the flexibility of processes Longer and Broader: required is an integrated approh extending ross the entire manufturing process (from raw material extrtion, transformation, to final recycling, disposal) - taking into count the entire lifecycle of the vehicle and whole supply chain - aiming towards the setting of new environmental standards. ECO sustainable = ECOefficient & ECOnomically-viable manufturing of next-generation, high-value-added products 2 2
New Materials and Manufturing Focusing Research tivities 1. New materials for product competitiveness Research on eco-sustainable materials is necessary for a wide range of systems and components concerning: - stringent performance, - end-of-life specifications, - cost requirements, - suited for efficient manufturing processes. Holistic approh is needed for analysis and simulation ross the entire value chain (from raw materials to final product production, use and recycling) Joint collaborative tivities of the OEMs are necessary in order to initiate the required scale of research tivities within the supply industry. 3 3
New Materials and Manufturing Focusing Research tivities Focus on material domains: from random to organized (fibres, composites, high strength steels, light alloys ) from sculptured to constructed (rapid and agile manufturing, rapid tooling, ) from discovery to creation: new tailored materials designed to product functions (nano-structured, multifunctional materials) 4 4
New Materials and Manufturing Materials domains from sculptured to constructed 5 5
New Materials and Manufturing Materials domains to creation from discovery Integrated display on device Deposition on substrate and single display fabrication Synthesis Displays based on inorganic nano-structured materials Nano Sub-micro Micro Mro 6 6
New Materials and Manufturing Focusing Research tivities 2.Green manufturing of today generation products Analysis of the full potential for exploitation of raw materials, taking into count the entire lifecycle and all constituent components. Decrease in energy consumption ross the entire supply chain in order to reduce the total environmental impt. Review on all resource-critical processes concerning exploitation, production and transformation of materials, including: - material extrtion - foundry or processing - forming, treating, finishing - assembly & disassembly - scrapping - recycling - heat generation - logistics,. 7 7
New Materials and Manufturing Focusing Research tivities 3. Affordable manufturing of next generation products Manufturing processes need to be verified regarding costs, time and quality. Future manufturing systems have to guarantee performance and robustness, despite increasing product variants and variable production volumes. Ftory-oriented frameworks have to be specified for further automation and robotics. Electric vehicles require specific attention regarding their constituent components and sub-systems including batteries. Research tivities need to focus on: - standardisation of components - modularisation of sub-systems - flexibility and agility of assembly 8 8
New Materials and Manufturing Focusing Research tivities 4. Intelligent manufturing for integrated product-process development The safety of manufturing will be increase by advanced sensor applications and software for volumetric protection on mhinery: - vision systems - intertion of operations with the workers - collaborative robots and mhinery intelligence for operator s safety Broad scope for ftories of the future in order to optimize the life-cycle including buildings, resources and production equipments. Standard automatic generation of mhinery programs and virtual validation considering the intertion with real mhine control. Image courtesy of Comau 9 9
New Materials and Manufturing Focusing Research tivities 5. Virtual engineering for integrated product-process development Methods and tools for the simulation of new and complex products and processes, including - materials - multi-domain behaviour - physical and cognitive human intertion Development of new approhes and methods for multi-domain optimisation Process driven product design Research topics: - Architectures - Product representations - Collaboration technologies - Virtual reality and augmented reality systems - Seamless link of representations, simulation and virtual reality environments. 10 10
New Materials and Manufturing Coherence with future funding programmes Research Priorities 1. New materials for product competitiveness 3. Green manufturing of today product generation 4. Affordable manufturing of next product generation PPP Ftories of the Future EXPLOITING NEW MATERIALS THROUGH MANUFACTURING SUSTAINABLE MANUFACTURING HIGH PERFORMANCE MANUFACTURING 5. Intelligent manufturing for integrated product and process development 6. Virtual engineering for integrated product and process development ICT ENABLED INTELLIGENT MANUFACTURING 11 11
New Materials and Manufturing for Product Life-Cycle Sustainability ECO-SUSTAINABLE DESIGN ECO-SUSTAINABLE MANUFACTURING 12 12
New Materials and Manufturing for Product Life-Cycle Sustainability Green and affordable manufturing of green and affordable product 13 13