The project has two main elements: developing a demonstrator and scaling up of the technology.
During the first period of the project the consortium has developed a concept for vehicle structure based on the EX-CORE technology. Material research helped determine the boundaries and performance of the structure geometry. Finite element calculations determined the CFRP layup and EX-CORE density distribution throughout the platform. The density and geometry was then broken down into smaller laboratory scale tests to determine the foam core "recipe". Goal was to keep the specific material properties high, whilst ensuring an industrial (short) process cycle.
The team have further refined the mold technology and process parameters to ensure high efficiency, short production cycle, reduced fall out and waste. The team tested large scale tooling solutions (metal) and small scale tooling solutions (CFRP tooling).
Parallel to this the team refined the business case to better respond to the changing market. Through conversations with OEM's and TIER suppliers the team learned that the industry is shifting its focus towards electric drivetrain technology and autonomous driving in the years to come. Platform production and material technology is therefor not a focal area. Although OEM's have indicated that this will become essential once battery technology has been adopted widely. The EX-CORE team has decided to develop a new strategy for short term growth: Co-development. Through a co-development the team is able to tailor the technology and design together with the OEM. Added benefit of this strategy is easy adoption and reduced risk. The production is outsourced via licensing. (Technology licensing was initially and still is the commercial goal of the project.) The team also widened the market by adding high growth markets such as aerospace (drones) and e-bikes to the scope to ensure initial cashflow. The company branding was designed to appeal to the target markets.
The commercial strategy was consolidated by the installation of the 400m2 production department at the Lelystad plant. Another 400m2 has been reserved for scale up. The production department includes an automated CFRP cutting machine, walk-in freezer for material storage, production area, EX-CORE mixing area with extraction, mold storage, etc. The department was inspected and approved by the Dutch health and safety authorities.
The team developed the injection strategy for EX-CORE and further refined the mixing station. The final production machine is currently in development. However, both concepts have already been tested in various prototypes.
In March 2020 the team launched EX-CORE to the target audience. The EX-CORE team is currently in discussion with aerospace, electric bicycle and car manufacturers regarding the adoption of EX-CORE.
