Vehicle parts: new technology to reduce time and cost
European car manufacturers, small and medium-sized enterprises (SMEs) and technology centres have teamed up to find a way to make more efficient and cost-effective automobile structure components. Under the EU-funded PROFORM ('An innovative manufacture process concept for a flexible and cost effective production of the vehicle body in white: Profile Forming') project, the consortium is developing a new technology that will speed up the production of components of different shapes while lowering the associated costs. PROFORM received almost EUR 6 million under the 'Nanotechnologies and nanosciences, knowledge-based multifunctional materials and new production processes and devices' (NMP) theme of the Sixth Framework Programme (FP6). Most automobile structural parts produced today use a forming technology ('stamping') that allows for the range of shapes needed to create a vehicle body. The major fallback with stamping, however, is the high cost associated with the tools required to manufacture a part. Additionally, the lack of flexibility inherent in the system means that a change in the shape of a piece at some point down the line requires a complete overhaul in the tooling process, resulting in loss of time and money. The aim of the PROFORM project, which started in November 2006, is to develop a new engineering and manufacturing concept based on integrating three types of forming technologies: flexible roll forming (RF), laser forming (LF) and electromagnetic forming (EMF). The team is using multifunctional materials, nano- and micro-technologies as well as process simulation, optimisation and control technologies to achieve its goal. The new technology, known as profile forming, will reduce both the time and costs involved in creating high-technology components for automobiles. It will accommodate 'profiles' with curved edges, conical shapes and variable sections to produce crossbars, beams and other vehicle components. In this way, the team states, 'New models and derivatives can be developed at low cost, and auto manufacturers can react flexibly to customer wishes at very little risk.' The PROFORM consortium is made up of some 20 partners from 5 EU Member States (Czech Republic, Germany, Spain, France and Italy), representing the breadth of expertise necessary to develop and implement the breakthrough technology. More than half of the participants are high-tech and industrial SMEs, producing components, equipment, tools, and process engineering and auxiliary devices. The team is also made up of car manufacturers, technological centres, and universities and research centres. An international conference is planned for 2010, at which results of PROFORM will be presented to industry, the scientific community and interested members of the public.