Case Study: Bentley

ECOGEL-CRONOS Partner Axon Automotive Produce Design for Door Module Skin for Prototype Bentley Motor Vehicle Project partner and tier one supplier, Axon Automotive, has now produced a design for a door module skin for a prototype Bentley Motor Vehicle. Axon explains that Bentley Motors was chosen as a potential customer as it is a niche vehicle supplier that produces volumes of 6,000 – 7,000 units per annum; allowing for a realistic composite TACKT time (approximately 12 minutes 9 seconds. 7000 units, 230 days, 435 minutes per day and 85% efficiency). The primary objective was to develop a technological solution that would lead to mass reduction (as will be required by the 2020 EU C02 emissions targets) ideally without incurring a cost penalty and preferably with a cost reduction. The door skin gives a large, thin, flat panel with a sweeping geometry. It is currently produced from steel but the new designs would see it being reproduced as a carbon fibre composite laminate to showcase potential mass savings. The powder gel coat will facilitate the A-class surface finish requirement that is tricky and costly to meet with conventional composites and gel coats. According to Axon, the skin thickness must be minimised to reduce material usage, whilst stiffness is optimised to reduce impact/deformation damage. It is expected that the design would result in a reduction in coating thickness on the part, and a more efficient paint process with the use of e-coating. The powder gel coat can be applied quicker thinner and with zero volatile organic compound (VOC) emissions when compared with existing gel coat solutions which results in: • Reduced part mass, material use and component TACKT time • Reduced feedstock cost • Reduced secondary processing cost (i.e. additional primer coats, hand finishing and rework)