1. 1
Innovations in Composite
Engineering & Light-weighting
Steve Fletcher - BEng (Hons) CEng MIMechE
Head of Engineering

2. 2
Company Overview
Consulting
Composite
Technologies
 Project Management
 Body Engineering
 FEA Simulation / Crash
 Light weighting
 EV Design
 High Volume Composites
 Cost Effective
 Tooling & Machining
 Integrated Composite Systems
 Trim Development
 Electrics & Electronics
 Prototype build
 Niche System Production
 Series Production
Special Operations

3. 3
Company Overview
ENGINEERING CENTRE
Coventry, UK
ENGINEERING OFFICE
London, UK
Pune, India
Accreditation
TS16949 : 2009
ISO9001 : 2008
Core Competencies
Consulting
Composite Technologies
Special Operations
Clients
Strategic Alliances
Cytec (Oct 2015)
Pricol Technologies (Jan 2015)

4. 4
History
2005
Management
buy out of P+Z,
Rebranded
Penso
Consulting
2006
Complete
interior design,
manufacture &
production
supply Brink
Carver ‘One’
2007
Fiat Professional
Specialist turnkey
vehicle programme
– engineer and
manufacture taxis
for UK public hire
sector
2008
Engineer and
manufacture
London Specific
Vito Taxi for
Mercedes Benz -
Full European Type
2 approval and
homologation
2009
Spyker C8 Aileron
complete vehicle
engineering,
interior trim and
convertible roof
system for Spyker
derivative.
2010
ISO9001 and
TS16949
accreditation
2011
Tier-1 supplier into JLR
 L538C Evoque Convertible
 L405 LWB
 CX75 engineering &
Composite Body
Structures
 X152X Prototype, Tonneau
 ETO engineering support.
 Project Donington
engineering and build.
 VARCITY Megacity.
2012
Supply of Production,
Interior Trim for
Morgan 3 Wheeler
2013
 Re-Accreditation
of ISO9001 and
TS16949
 Support Product
Launch L405 LWB
2014
 L538C
 L538C ADV
 CDRM Models
 P231
 SP1 L322
 SP2 L405
 X261
SP = Special Project
2015
 Bimini Hood
 X590
 X760 LCN
 CF Train Door

5. 5
Company Growth
Turnover
 Penso has grown rapidly over last few
years – diverse customer base.
 Turnover tripled over last 5 years
 Forecast for 2015: £32m
 Growth supported by renaissance in UK
based Manufacturing.
 UK Government Support
 National (Innovate UK)
 Local (City Council)
 Legislation is driving need for lower
emission vehicles.

6. 6
Lightweight Composites
From prototype to volume production

7. 7
Lightweight Composite Technology
EU CO2 Legislation as ‘Technology Driver’
 Average UK new car CO2 emissions & EU
new car CO2 regulation targets
 2020: 95g/km (legislation)
 2025: 75g/km (under review)

8. 8
Composite Enabling Technologies

9. 9
Composite Enabling Technologies
Design for Performance,
Manufacturing & Cost

10. 10
 Process flow developed over the last 5
years on multiple composite
engineering programmes
 Concept Engineering
- Primary joint and beam stiffness and
strength calculated.
 Detail Design Engineering
- Full ply stack definition and
optimisation
 Manufacturing Engineering
- Producibility assessments
- Cuts & Darts
- Automated Ply-Book generation and
digital data output
State of the Art Design & Simulation Tools & Processes
Design for Performance, Manufacturing & Cost

11. 11
 Advanced Simulation Tools
- Crashworthiness
- NVH
- Durability
- Optimisation
 State of the art materials modelling
methods
- Penso materials modelling methods
developed from existing ASTM
methods to align with latest technology
requirements
 Advanced toolset allows detailed
analysis of joints and ply stacks
Simulation Methods for Composites
Design for Performance, Manufacturing & Cost

12. 12
 Advanced simulation technologies applied
 Material card data developed to enable predictive
methods.
- Tests are developed variants of ASTM standard
methods.
Composites Crashworthiness Simulation
C-X75 30FFB Crash C-X75 30FFB Crash
Penso Material
Development Process
Design for Performance, Manufacturing & Cost

13. 13
Optimisation setupOptimisation - Initial
Laminate Optimisation
Continuous phase - 1Continuous phase - 2Continuous phase - 3Continuous phase - 4Continuous phase - 5Continuous phase - 6Continuous phase - 7Continuous phase - 8Continuous phase - 9Continuous phase - 10Continuous phase - 11Continuous phase - 12Continuous phase - finalOptimisation Discrete phaseRationalise Optimisation
results
Design/manufacture requirementsManual optimisation
Local reinforcement for
attachment points
Final layup
C-X75 Tub
Includes Penso developed algorithms to optimise for Material & Process
costs in parallel with mechanical performance and weight
Optimisation
Triangle
Weight
Performance
Cost
Design for Performance, Manufacturing & Cost

14. 14
C-X75 Phase 1 Body Actual
BIW Weight: 160kg
BIW Torsion Mode: 75Hz
Torsional Stiffness: 56kNm/o
Bending Stiffness: 15kN/mm
Suspension Local k’s: 14-59kN/mm
Lamborghini Aventador
249.5kg (+56%)
44.9Hz (-40%)
35kNm/o (-38%)
Performance Benefits
Design for Performance, Manufacturing & Cost

15. 15
Manufacturing Processes:
Preform & Lay-up Automation
Composite Enabling Technologies

16. 16
1. Raw material
defrost
2. Nesting and
kit cutting of parts
(Pattern cutting)
4. Preforming
and Trim
3. Ply stack
7. Trimming
(5-Axis CNC)
5. Advanced
demould
6. Press forming
(Hot Compression
Mould Press)
demould & set up
8. Sample
Inspection
PPCP – Process Development

17. 17
<10 min cycle time
Preforming
(Penso alternate method)
and Trim
Ply stack
(Penso alternate technology)
Trimming
(5-Axis CNC)
using alternate method
Advanced
demould
(Penso alternate method)
Press forming
(Hot Compression
Mould Press),
demould & set up
27 min 15 min 25 min 10 min 20 min
Preforming
(vacuum bladder)
and Trim
Laminating Trimming
(5-Axis CNC)
using manual fixings
Demould Press forming
(Hot Compression
Mould Press),
demould & set up
<10 min <10 min <10 min <10 min <10 min
INITIAL PROCESS
IMPROVED PROCESS
27 min cycle time
PPCP – Process Development

18. 18
10 min
cycle time
PPCP – Process Development
5. Demould
(Penso alternate method)

19. 19
Hot Compression Moulding
High Pressure Resin Transfer Moulding
Composite Enabling Technologies

20. 20
Hot Compression Moulding & High Pressure Resin Transfer Moulding
 High tonnage press facilities with
large platen formats, allowing the
production of large integrated
components.
 High pressure RTM equipment
automatically linked to specific
presses.
 Ultrasound NDT Equipment for panel
inspection. (Lamination
characteristics, bonding
characteristics)
 Inspection Booth
Composite Enabling Technologies

21. 21
Penso’s Lightweight Technology
 State-of-the art hot
compression moulding
 Cycle times <7
minutes
Press forming
10 registered patents suited to use in the
automotive, rail and aerospace industries
HP-RTM
 State-of-the art high-
pressure resin transfer
moulding
 Cycle times <5 minutes
Composite Enabling Technologies

22. 22
Simultaneous Tooling Development
 Substantial Research and
Development into manufacturing
processes for high volume CFRP
production, simultaneously aligned
with tooling development to suit
product performance and cost
requirements.
 Tooling in aluminium
 Low volume production using
aluminium tools
 High volume production using steel
tooling
Composite Enabling Technologies

23. 23
Simultaneous Tooling Development
 Substantial Research and
Development into manufacturing
processes for high volume CFRP
production, simultaneously aligned
with tooling development to suit
product performance and cost
requirements.
 Tooling in aluminium
 Low volume production using
aluminium tools
 High volume production using steel
tooling
Composite Enabling Technologies

24. 24
Further Development & Growth
Penso next investment
 Composites press facility expansion
with semi-automated and fully
automated press lines.
 Fully automated BIB assembly
facility
 Tool Room expansion for increased
capacity requirements
 Full “turnkey” composites facility from
product engineering through to
volume production supply.

25. 25
Steve Fletcher
Head of Engineering
steve.fletcher@penso.co.uk
M: +44 (0)7508 225 762
Penso Consulting Ltd
Woodhams Road
Coventry
Warwickshire
CV3 4FX
United Kingdom
T: +44 (0)2476 217760
www.penso.uk.com
www.linkedin.com/company/penso
www.twitter.com/PensoGroup