References from the automotive industry

For shell constructions, drive trains and chassis, fibre composite materials pave the way for technical and economic advantages over metallic constructions. Combined with drastic increases in the cost of raw materials, legally required reductions in exhaust emissions, shorter model cycle periods and increasing demand for niche vehicles, construction with fibre composite materials presents a sensible alternative to lightweight metal concepts.

Development and series production of the external side frame for the BMW i8 Roadster
BMW has the worldwide technology leadership for the production of CFRP components and use in vehicles; accompanied by the highest demands on production technology and quality. We are therefore very proud that BMW has nominated us to produce the side frames left / right for the i8 electric sports car. The series start was in the first quarter of 2018, approx. 2.600 sets are manufactured per year at ACE.

Entwicklung und Serienfertigung des Gelenkwellengehäuse für den Mercedes-AMG GT R

ACE hat den Zuschlag von Mercedes-AMG für die Entwicklung und Fertigung des CFK-Torque Tube bekommen. Der Torque Tube wird in einem Schuss im sogenannten RTM Verfahren (Resin Transfer Moulding) hergestellt.

Audi AG
Development and series manufacturing of the MSS Tunnel and the B-pillar for the models Lamborghini Huracan and the new R8 Spyder (coupe´+ spyder)

ACE was nominated by Audi to develop and manufacture crash relevant CFRP parts for the new car body “MSS”. Internaly we call the parts MSS tunnel and the associated crash-cover. The tunnel is manufactured by the RTM process, the crash-cover by the carbon SMS process. Depending on the tunnel variant there are up to 25 studs be applied in a full automatic Tucker method. In addition to these components, ACE is going to manufacture the B-pillar (outside) of the R8 successor. This part will be produced by the RTM process as well. The annual production rate is for approx. 1.200 Huracan and 2.000 R8 per year (each, coupe and spyder). If necessary, the production rate can be extended.

AMG / Daimler AG
Development and production of the spare tire well for the Mercedes AMG S63 and S65 models

For AMG, the factory tuner of Damiler, ACE has developed a spare wheel compartment for the S63 and S65 models . The "Emulde" is a single-shell part with a sandwichcore. It is produced by the RTM process. The production is designed up to around 4.000 parts per year.

Automobili Lamborghini Spa
Development and production of CFRP components at the rear of the Aventador Spyder

ACE has developed seven different components at the rear of the Aventador Spyder in a class A surface. It involves the engine bonnet with cover, the bonnet frame and the side flaps and fender covers (left + right). All components are made by the RTM process . The production is designed to around 1.000 parts per year.

Volkswagen AG
Development and series production of CFRP components for the "one -liter car " VW XL1

The VW XL1 is the " one-liter car " of the Volkswagen AG. As of 2002, Volkswagen was working on the concept and began with the production in March 2014. ACE was charged with developing and prototyping of the rear fender in a class A surface. Due to the undercuts a complex RTM tool was made with sliders. For the development of the fender Volkswagen and ACE were awarded with the 1st prize at the SPE Innovation Award 2012 . In the further course of collaboration ACE got the order to produce base plates in a small series of 250 pieces.

Development and series production
of CFRP components for the rear of the Aventador

For the Aventador, the successor to the Murcielago, ACE manufactures the bonnet panels, side flaps, cover fenders and engine bonnet from CFRP. These lightweight components are produced using the RTM process and lead to overall weight savings of approx. 30 %. The series production process is designed for approx. 1,000 sets per annum.

Daimler AG
Series production of the CFRP inner shell for the SL AMG

ACE worked together with Daimler AG to develop the design of the inner shell of the SL AMG's engine bonnet in CFRP. Here, the partial carbon styling is required to meet special requirements. ACE manufactures the series for Daimler AG, producing up to 30 units per day.

Audi AG
Development and series manufacture of the CFRP engine bonnet and the side panels for the R8 Spyder

In cooperation with Audi AG, ACE developed the soft-top compartment cover and the side panels (fenders) for the Audi R8 Spyder, built using CFRP. Today, ACE manufactures these components for the R8 Spyder using the RTM process and is also responsible for paintwork and assembly as a system supplier.

Automobili Lamborghini Spa
Development and series production of the Gallardo Spyder's CFRP tailgate

In cooperation with Lamborghini and Audi AG, ACE developed a tailgate made of carbon fibre (CFRP) with Resin Transfer Moulding (RTM) production technology, bringing the tailgate to series production in late 2005. The company faced a particular challenge here in terms of manufacturing: meeting the stringent requirements of Class A surface quality while also achieving strongly contoured surfaces, including, among others, the typical Lamborghini slats. Thanks to the CFRP construction, a design could be realized that would not be possible using a metal structure, and a 30% weight saving was achieved. Approx. 1,500 tailgates are manufactured per year at ACE

Bugatti Automobiles S.A.S.
Development and series production
of the CFRP side panels for the Bugatti Veyron

ACE was involved in various development aspects of the composites for the Bugatti Veyron, the 1,001 PS "street-legal racing car". The CFRP exterior skin parts (side panels) are now in series production. The utmost value is placed on the surface quality of the components for this highly exclusive vehicle.

Porsche AG
Development and series production of
CFRP parts for the Porsche Carrera GT

During the development phase for the Porsche Carrera GT, ACE was a firm development partner with a focus on lightweight construction and acted as a specialist in fibre composite materials. As a development partner, we supported the Porsche development team in the fields of design, dimensioning and material selection and qualification. In preparation for production, we supported Porsche in developing the tool concept and then carried out series production of a total of 6,000 carbon fibre stiffener elements.

Hymer AG
Development of lightweight construction concepts for mobile homes

Within the framework of a development contract, we investigated the use of FRP construction for the front section of a Hymer mobile home.

Liebherr GmbH
Composite developments for Liebherr mobile cranes

Weight reduction is also growing in significance in the heavy goods vehicle sector. In the commercial vehicles sector, ACE therefore worked in cooperation with Liebherr to develop a complete composite crane cabin and cabin doors, as well as manufacturing prototypes. RTM technology was once again used as the manufacturing process here

As well as the reference projects mentioned here, many of our engineers also have further development experience in automotive construction from projects at EADS-Dornier.

Unimog UX 100 and U200/300 with CFRP cabin
using RTM construction

The FRP cabin of the Unimog UX 100 and U200/300 represents a new development in the field of automotive construction. Weighing just 70 kg, the bodyshell structure of the UX 100 consisted of only eight components, manufactured using the RTM process and then glued together to form the structure. This construction allowed the cabin to satisfy all relevant regulations (EEC, ECE-R29) and tests (impact testing, etc.). The CFRP cabin entered series production at 1,000 cabins per annum (UX 100). The bodyshell structure of the Unimog consisted of only nine components with a total weight of around 150 kg. The CFRP cabin entered series production at around 2,500 cabins per annum.

Development and construction of prototypes of a CFRP hardtop for the Mercedes SL

Following construction of a hardtop prototype for the Mercedes SL, the development of the RTM production concept was designed for a quantity of 13,000 units per annum. At 10 kg, the entire structure of the hardtop was around 30% lighter than an equivalent aluminium construction and, following a standard painting process, satisfied the requirements of Class A surfaces. Furthermore, Cardan shafts made of CFRP were developed for the SL; these were manufactured using multiple-coil winding processes and tested. The flange connection was realized using cost-effective injection-moulding technolog