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3rd-AnnualAutomotive Composites :45-2:152:15-2:452:45-3:15W E D N E S D A YAuditoriumAmplitheatre 101ENABLINGTECHNOLOGIES IADVANCES INREINFORCEMENTS IBONDING & JOININGAllen Peng,Yorker Chang,Anthony Yang,Venny Yangand Fu Chin ChuangO. Khondker, U.S. Ishiaku,and H. HamadaA. Droste, P. Naughton, B. Bowser,J. Röttger, S. Burr, O. Imam, M. Zeitler,T. Heuft, and A. CawleyCoreTech System Co. &DSM Engineering PlasticsKyoto Institute of TechnologyDow Automotive3D Fiber Orientation & WarpageAnalysis of Injection-MoldedThrottle ValveFabrication, Processing &Mechanical Properties of FlatBraided Thermosetting CompositesUsing Natural & Coated Jute YarnBonded Metal-Plastic CompositeStructures – the future of lightweight,cost-effective performanceChristopher Rush, Joe Falqueand Karen McRitchieA. Nakai, D. Nakaami,T. Narita,H. Hamada and E. FukuiLynn Klett and Darrell HerlingGalorath Inc.Kyoto Institute of Technology& Fukui Gyomo Co., Ltd.Oak Ridge National Laboratory andPacific Northwest National LaboratoryReal Time Cost Impact Assessment ofComposite and Metallic DesignAlternativesFabrication and MechanicalProperties of Multi-Axial WarpKnitted Thermoplastic CompositesUsing Micro-Braided YarnJoining Composite Chassis Componentson Heavy TrucksKaren Taminger and Robert A. HafleSharad Kumar andKrishnamurthy JayaramanK. Sugimoto,A. Ochi,A. Nakaiand H. HamadaNASA Langley Research CenterMichigan State UniversityKyoto Institute of TechnologyElectron Beam Freeform Fabrication:A Rapid Metal Deposition ProcessPerformance of PP/ClayNanocomposites with EdgeFunctionalized ClayMechanical Properties of Matrix HybridComposites with Mechanical JointCOFFEE BREAK & EXHIBITSLUNCH & EXHIBITSLobbyLobbyKeynote Speaker - William G. Abbatt, Brooks Kushman P.C.Strategies for Intellectual Property Protection and Assest ManagementENABLINGTECHNOLOGIES IIADVANCES INREINFORCEMENTS IIPROCESSING IIRick DoveJon JacobsonStephen T. BowenProMetal Division of Extrude HoneSchmelzer Industries, Inc.PlastiComp, Inc.Conformal Cooling with SolidFreeform Fabrication Technology:Issues and OpportunitiesSurface Profile and Surfacing Veil:Reducing Printout with aResin-Rich SurfaceCompounding with “Pushtrusion”TechnologyDavid Stewart and Xia-Yang ShengMark GoldhawkChangsheng Gan, Ronald F. Gibsonand Golam M. NewazStewart Automotive Research, LLCDow AutomotiveWayne State UniversityElectron Beam Welded ToolingCarbon Fibre/RRIM Compositesfor Exterior Automotive ApplicationsEnergy Absorption in ThermoplasticallyStamped Composite Grid StructuresOFFEELanhong Xu,Tom Maseand Lawrence DrzalStephanie Ader and Rodolphe MalletCOFFEE BREAK & EXHIBITSLobbyWei XieTA InstrumentsMichigan State UniversityInoPlastic OmniumApplications of Thermal Analysis inPolymer & Composites CharacterizationImproving Adhesion BetweenCarbon Fibers and Vinyl Ester ResinsUse of Composites for Rear Closures3:15-3:453:45-4:006Amplitheatre 102Hiroyuki Fukushima and Lawrence Drzal, Michigan State UniversityGraphite Nanoplatelets to Improve the Mechanical Electrical and ThermalProperties of PolymersCLOSING - Renita JonesAuditorium

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3rd-AnnualAutomotive Composites Conferencec o n f e r e n c eP R E S E N TAT I O N SKEYNOTE SPEAKERSComposites, Today & Tomorrow: An Editor's Eye View Steve LoudComposites News InternationalThis keynote address reviews the major composites marketsfor advanced materials with attention to the role significantapplications play. Composites in High Performance CarsFabrication and Mechanical Properties ofMulti-Axial Warp Knitted ThermoplasticComposites Using Micro-Braided YarnDavid HillGeneral Motors CorporationThis keynote address discusses the challenges and opportunitiesoffered by advanced materials for use in vehicles with higherrequirements for quality, appearance, cost efficiency, developmenttime, and styling flexibility. Economics as a Tool for Technology Development:Making Cost an Engineering VariableDavid StewartStewart Automotive Research, LLCThis keynote address discusses the importance of usingtechno-economic analysis as another dimension in engineeringoptimization to guide the decision-making process, reducingrisk and increasing the yield of research. Strategies for Intellectual Property Protectionand Asset ManagementWilliam G. AbbattBrooks Kushman P.C.This keynote address discusses management of a company’sintellectual property assets, including the substantive tasks integrally involved in a company’s IP endeavors, the procedural andreporting tasks, and a proposed model for allocating both thesubstantive and procedural tasks. ADVANCEMENTS INREINFORCEMENT TECHNOLOGYImprovements in Impact and Abrasion Performanceof Glass Fiber Thermoplastics by the LocalizedIntroduction of Self Reinforced PolypropyleneDerek Riley and Renita JonesBP– Curv CompositesThis presentation discusses the use of a highly impact resistant,self-reinforced polypropylene composite to provide localized reinforcement in GMT and LFT components without increasingweight or compromising recyclability. 8Fabrication, Processing & Mechanical Properties ofFlat Braided Thermosetting Composites Using Natural& Coated Jute YarnO. Khondker, U.S. Ishiaku & H. HamadaKyoto Institute of TechnologyThis presentation discusses studies on the tensile andbending properties of flat braided thermosettingcomposites using jute yarns.Asami Nakai, Dai Nakaami, Tsutom Narita,Hiroyuki Hamada and Eisuke FukuiKyoto Institute of Technology and Fukui Gyomo Co., Ltd.This presentation discusses research to fabricate multi-axial,warp-knitted thermoplastic-composite panels via a microbraiding technique. Performance of PP/Clay Nanocompositeswith Edge Functionalized ClaySharad Kumar and Krishnamurthy JayaramanMichigan State UniversityThis presentation discusses studies evaluating the use of threedifferent clays on the mechanical properties of melt-processedPP/clay nanocomposites. Surface Profile and Surfacing Veil:Reducing Printout with a Resin-Rich SurfaceJon JacobsonSchmelzer Industries, Inc.This presentation discusses the use of a surfacing veil for FRPlaminates to dramatically reduce resin shrinkage at the surface,improving surface finish as well as speeding resin flow inclosed tools, reducing demold times, protecting pultrusion dies,strengthening the gel coat, and improving bonding of the gelcoat to the reinforcement. Carbon Fibre/RRIM Composites forExterior Automotive ApplicationsMark GoldhawkDow AutomotiveThis presentation discusses the benefits of using carbonfiber in RIM polyurethane/polyurea composites to reduceweight, with discussion of processability, moldability, physicalproperties, paintability, and functional manufacturing forexterior body panels.

Society of Plastics EngineersAutomotive & Composites Divisionsc o n f e r e n c eP R E S E N TAT I O N SImproving Adhesion between Carbon Fibersand Vinyl Ester ResinsMechanical Properties of Matrix HybridComposites with Mechanical JointLanhong Xu, Tom Mase and Lawrence DrzalMichigan State UniversityThis presentation discusses the influence of matrix cure-volumeshrinkage on adhesion between carbon fiber and vinyl-ester resinsand the benefits of a specially formulated epoxy-sizing agent tocounteract such shrinkage. Graphite Nanoplatelets to Improve the MechanicalElectrical and Thermal Properties of PolymersHiroyuki Fukushima and Lawrence DrzalMichigan State UniversityThis presentation discusses development and use of cost-effectivegraphite nanoplatelets to improve the thermal, mechanical, andelectrical properties of polymer nanocomposites for use in fuelcells, batteries, and electrical-shielding components. BONDING & JOININGAdhesively Bonded Structural Compositesfor Aston Martin VehiclesJohn HillFord Motor CompanyThis presentation discusses the role of adhesives in the AstonMartin V12 Vanquish, a vehicle that is entirely bonded togetherwith adhesives and makes use of 20 composite parts. Bonded Metal-Plastic Composite Structures the future of lightweight, cost effective performanceA. Droste, P. Naughton, B. Bowser, J. Röttger, S. Burr,O. Imam, M. Zeitler, T. Heuft and A. CawleyDow AutomotiveThis presentation examines use of bonded metal-polypropylenecomposite structures for applications where stiffness, impactresistance, and functional integration are required as well aslower cost and weight. Joining Composite Chassis Componentson Heavy TrucksLynn Klett and Darrell HerlingOak Ridge National Laboratory and Pacific NorthwestNational LaboratoryThis presentation discusses work to overcome the majortechnical issues associated with joining thick fiber-reinforcedcomposite sections, especially where it is important to haverobust and economical attachment techniques to joincomposite parts to steel. Kenichi Sugimoto, Akihiro Ochi, Asami Nakaiand Hiroyuki HamadaKyoto Institute of TechnologyThis presentation discusses the effects of using various stackingsequences and laminate thicknesses on the mechanical behaviorof hybrid-composite parts for automobiles.COMMERCIAL TRANSPORTThe All Composite One Piece BumperBrian KnouffDelphi Advanced Composites EngineeringThis presentation discusses the benefits of using single-piececomposite bumpers – which are compatible with the newproduction environment – to replace steel or thermoplasticsfor Class 8 trucks. Composite Use in Heavy TrucksEdward ZenkInternational Truck & Engine Corp.This presentation provides an overview of composite use inheavy trucks in terms of new materials, new processes, andnew applications. Heavy Vehicle Mass Reduction Utilizing PolymerCompositesCliff Eberle and Mark T. SmithOak Ridge National Laboratory and Pacific NorthwestNational LaboratoryThis presentation discusses new DOE funding initiatives for usingpolymer composites to reduce mass in Class 8 trucks as a platformfrom which to subsequently migrate validated technology topassenger-vehicle use. ENABLING TECHNOLOGIESDesign and Optimization of ConformalCooling PassagesRavi Mayavaram, Mahender Reddy, David Stewart and John Tolle,Altair Engineering, Inc. and Stewart Automotive Research, LLCThis presentation discusses a new approach to optimizing moldcooling via a seamless combination of simulation and optimization tools under a unified framework. 9

3rd-AnnualAutomotive Composites Conferencec o n f e r e n c eP R E S E N TAT I O N S3D Fiber Orientation & Warpage Analysisof Injection-Molded Throttle ValveAllen Peng,Yorker Chang, Anthony Yang, Venny Yangand Fu Chin ChuangCoreTech System Co., Ltd. and DSM Engineering PlasticsThis presentation discusses the development of a new 3Dtechnique for modeling fiber orientation and anisotropy forinjection-molded plastics. Real Time Cost Impact Assessment of Composite& Metallic Design AlternativesCarbon Fiber: The Automotive Material of theTwenty-First Century Starts Fulfilling the PromiseDale BrosiusBrosius Management ConsultingThis presentation provides an overview of the current state ofcarbon fiber usage in automobiles in Europe, North America,and Japan, ranging from exotic "supercars," to niche vehicles,to mass-production applications. Christopher Rush, Joe Falque and Karen McRitchieGalorath IncorporatedThis presentation discusses use of a process-based parametric costmodel to evaluate real-time cost-impact assessments of compositesand metallic design alternatives.Composite Design Procedures for Racing CarsElectron Beam Freeform Fabrication:A Rapid Metal Deposition ProcessDevelopment of the Class-A Carbon Fiber Hoodfor the 2004 Chevrolet Corvette Z06 Karen Taminger and Robert A. HafleNASA Langley Research CenterThis presentation discusses a new layer-additive process forfreeform fabrication of various metallic structures via electronbeam technology. Conformal Cooling with Solid FreeformFabrication Technology: Issues & OpportunitiesRick DoveProMetal Division of Extrude HoneThis presentation compares benefits and attributes of varioussolid freeform rapid-tooling technologies for use in theproduction of plastic tooling. Electron Beam Welded ToolingMario SacconeDallara AutomobiliThis presentation discusses procedures for designingcomposite parts for racing cars. Mark Voss, John Remy and Nancy PottishGeneral Motors Corporation and MacLean Vehicle SystemsThis presentation discusses development and validation of acarbon-fiber hood – the first original-equipment painted CFexterior body panel on a production vehicle – for the ’04model year Corvette. Composites in the Cadillac XLRDavid LeoneGeneral Motors CorporationThis presentation discusses selection and engineering ofcomposite materials for the Cadillac XLR that enabledGeneral Motors to enhance luxury and increase performanceof this vehicle. David Stewart and Xia-Yang ShengStewart Automotive Research, LLCThis presentation discusses the cost-saving use of electron beamwelding to construct large tools that also deliver features such asconformal cooling and allow for the use ofhigh-performance steels.Class A Carbon Fibre Reinforced Plastic (CFRP)Body Panels on the MG Rover SVApplications of Thermal Analysis inPolymer & Composites CharacterizationCarbon/Epoxy Composites for theLamborghini Murcielago Wei XieTA InstrumentsThis presentation describes the use of thermal analysistechniques for the design, optimization, technical support,and QA/QC of polymers and polymer composites. 10LEADING-EDGECOMPOSITE VEHICLESJoe SummersSP SystemsThis presentation discusses the rapid development of carbonfiber-reinforced syntactic resin body panels for the MG Rover SV. Attilio Masini and Paolo FeraboliAutomobili Lamborghini S.p.AThis presentation discusses the development of carbon / epoxybody panels and structural components for the LamborghiniMurcielago that are joined to the tubular steel chassis via hybridadhesive bonding.

Society of Plastics EngineersAutomotive & Composites Divisionsc o n f e r e n c eP R E S E N TAT I O N SNEW APPLICATIONSNew Application Technologies in PhenolicMoldable CompositesWillem Lossy and Phil BeasleyVyncolitThis presentation discusses the benefits of new-generationphenolic molding compounds vs. thermoplastics and metalsin various engine and powertrain applications. Development of the Fiber Reinforced ThermosetDaimlerChrysler 4.7L V-8 Engine Valve CoverSteve Crawford, Mark Dixon and Paul GramannDaimlerChrysler, Dana Corporation and TheMadison Group: PPRCThis presentation discusses the rapid design and developmentof a glass-reinforced vinyl ester thermoset composite for use in anew V-8 engine-valve cover, replacing a die-cast magnesium partat lower cost and weight. New 2-Layer Automotive Body-Panel SystemUsing Lightweight Thermoplastic CompositeBackside & Aesthetic SurfacesH. Dittmar, T. Hofmann, D. LoPresti, B. Vos and D. UrbanQuadrant Plastic CompositesThis presentation discusses work on a two-layer body-panelsystem using a new, lighter weight thermoplastic compositebackside and an aesthetic surface layer – either precoatedaluminum or inherently colored thermoplastic or paint films –to meet Class A surface requirements for body panels. Advanced Technologies for Design and Fabricationof Composite Automotive ComponentsScott Wellman, Ron Averill and Johanna BurgueñoNVH Concepts and Red Cedar TechnologyThis presentation discusses the benefits of combining advancedmanufacturing and design methods to realize novel compositesolutions at a fraction of the weight of equivalent metal parts. Carbon Fiber Composite Applications forAuto IndustriesTetsu Kyono,Yukitane Kimoto and Yasuyuki KawanomotoToray Composites (America), Inc.This presentation discusses the design and development of acarbon-fiber composite drive shaft, which provides weight and noisereduction and increased safety for a rear-drive passenger vehicle. One Piece DLFT Automotive Running BoardsCharles Weber, Scott Ledebuhr and Garek BarumComposite Products, Inc.This presentation discusses development of a one-piece compositerunning board – via a patented in-line compounding technology– which replaces a 43-piece metal and plastic assembly at significant cost savings and half the weight. NEW MATERIALSTCA and Contributions Made to ImproveSMC PaintabilityMichael SiwajekThyssenKrupp Budd CompanyThis presentation discusses analysis work done to discoverthe root cause of defects in painted SMC parts, efforts totoughen the resin matrix to enhance paintability, subsequenttesting, and current commercial applications that benefitfrom this technology enhancement. Tough Sheet Molding CompoundLora MasonAshland Specialty Chemical CompanyThis presentation discusses a new SMC formulation specificallydeveloped to be more durable and resilient to micro-cracking,which is the primary source of paint problems in SMC partsrequiring a Class A surface. Renewable Source Materials Phase IIPeter W. VaccarellaAshland Specialty Chemical CompanyThis presentation discusses Phase II work on soy-based polyestersoriginally developed as SMC for farm-equipment applications andnow being evaluated for spray-up, infusion, and RTM processes. Recent Developments in High PerformanceThermoplastic CompositesKlaus Gleich and Allan MurraySouthern Research Institute and Ecoplexus, Inc.This presentation provides an overview of currenttechnologies for producing high-performance thermoplasticcomposites, including properties, processing steps, benefits,and typical applications. 11

3rd-AnnualAutomotive Composites Conferencec o n f e r e n c eP R E S E N TAT I O N SBiobased Poly(trimethylene terephthalate):Opportunity in Structural Composite ApplicationsPROCESSINGA. K. Mohanty, W. Liu, L. T. Drzal, M. Misra, Joseph V. Kurian,Ray W. Miller and Nick StricklandMichigan State University andE. I. du Pont de Nemours and Company, Inc.This presentation discusses work on injection moldablecomposite materials based on PTT and glass, whose propertiesmay make them suitable for structural applications in automotiveand building-product applications.Structural RIM Choices for Today's Automotive Design Bio-Based Epoxy/Clay Nanocomposites as aNew Matrix for Carbon Fiber ReinforcedComposites: Thermophysical and MechanicalProperties EvaluationsH. Miyagawa, A. K. Mohanty, M. Misra, and L. T. DrzalMichigan State UniversityThis presentation discusses work on bio-based epoxynanocomposites reinforced with organo-montmorilloniteclay and carbon fiber. Terry Seagrave, Bayer Polymers LLCThis presentation discusses two traditional technologies and onenew honeycomb-core composite technology that have evolvedout of extensive research with SRIM over the past two decades. N

Renita Jones Chair - 2003 SPE Automotive Composites Conference North American Product Manager, BP-Curv Composites . Ford Motor Company dhousto2@ford.com 313-323-2879 Commercial Transport Al Murray Ecoplexus . Attilio Masini & Paolo Feraboli Tom Balch,Karl Gust Charles Weber,Scott Ledebuhr and John Gilbert and Garek Barum