JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 16

automotive

The Volkswagen XL1 super efficient vehicle

the highly safe monocoque.
A total of 21.3% of the new XL1,
or 169 kg, consists of CFRP. In
addition, Volkswagen uses lighthigher part volumes − because
weight metals for 22.5% of all
it can be automated. The RTM
parts (179 kg). Only 23.2% (184
parts are produced in multi-shell, kg) of the new XL1 is constructheated and vacuum-sealed tools. ed from steel and iron. The rest
This involves injecting liquid
of its weight is distributed among
resin at high pressure into the
various other polymers (e.g.
tool containing the semi-finished polycarbonate side windows),
carbon material, whose interior
metals, natural fibres, process
has the shape of the part to be
materials and electronics.
produced. The part then cures in Thanks to CFRP, the XL1 is not
the mould.
only light in weight, but very safe
as well. This is due in part to the
CFRP paves the way for
high-strength CFRP monocoque that is also lightweight. In
the future
The Volkswagen weighs just 795 a crash, it provides the necessary
kg, of which 227 kg represent the survival space for the driver and
entire drive unit including the
passenger. This is achieved by
battery, 153 kg the running gear, intelligent design of load paths,
80 kg the equipment and 105 kg including the use of sandwich
the electrical system. That leaves structures in the monocoque.
230 kg, which is precisely the
In addition, the front and
weight of the body - produced
rear aluminium car structures
largely of CFRP − including
absorb a large share of the crash
wing doors, front windscreen
energy. These principles were
with thin-glass technology and
also implemented in the design

The XL1 is a fuel-efficient car made of large, lightweight and strong carbon-fibre-reinforced polymer
(CFRP) parts.

T

he new Volkswagen XL1
Super Efficient Vehicle
(SEV) was unveiled
at the Qatar Motor Show in
2011. Pioneering construction
techniques, an advanced plug-in
hybrid drivetrain and innovative
packaging all play a part in allowing the XL1 to return 0.9 l/100
km on the combined cycle while
emitting 24 g/km of CO2 to set
a new benchmark for vehicle
efficiency.
The monocoque with its slightly
offset seats for driver and front
passenger, all exterior body parts
and functional elements such as
the anti-roll bars are all made of
CFRP. The preferred process for
producing CFRP components
at Volkswagen is Resin Transfer
Moulding (RTM). The density
of this material, or its specific
gravity, is only around 20% that
of a comparable steel exterior
skin. The CFRP parts exhibit a
level of stiffness and strength that
is by no means inferior to that of
comparable steel or aluminium
parts, yet the exterior skin of the
XL1 is just 1.2 mm thick.

Innovative RTM process
Compared to other CFRP
manufacturing methods such as
prepreg processes, RTM is more
economical − with lower costs at

RTM is more economic than others processes

16 jec composites magazine / No84 October 2013

of the CFRP doors, where an
aluminium impact beam is used
to absorb crash energy; a stiff
CFRP door frame also minimises intrusions into the CFRP
safety cell. Much attention was
given to the rescue of occupants
as well. If the XL1 is resting
upside down on its roof after a
rollover accident, pyrotechnic
separating screws simplify opening of the doors (swing doors).
The XL1 is manufactured (lefthand drive only) at Volkswagen's
Osnabrück factory in Germany
(which also produces the Golf
Cabriolet and Porsche Boxster).
Unlike these cars, the XL1 is
'handcrafted' using small series
production processes. An initial
production run of 250 XL1 vehicles will be made. Pricing and
sales channels are yet to be confirmed. The new car is currently
one of the most fuel efficient and
eco-friendly automobiles. n
More information:
www.volkswagen.co.uk


http://www.volkswagen.co.uk

JEC COMPOSITES MAGAZINE - Issue #84 - October 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #84 - October 2013

Cover
Edito
Point of view: global player
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
APPLICATIONS
Industrial
Security
Automotive
MARKET
Trends
Bio-based
Basalt
FEATURE MARINE
Simulation
High-performance
TPT
Natural fibre
Core materials
Hybrid composite
China
RESEARCH & DEVELOPMENT
Curing agent
Delamination
TECHNOLOGY & INNOVATIONS
P.U.
Services
VARTM
Metrology
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Point of view: global player
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 9
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Ad1
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Ad2
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 11
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Industrial
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 13
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Security
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 15
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Automotive
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Trends
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 19
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Bio-based
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Basalt
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Simulation
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 25
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - High-performance
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 27
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 28
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - TPT
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 32
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Natural fibre
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 34
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 35
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Core materials
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Hybrid composite
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - China
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Curing agent
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 43
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Delamination
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 45
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 47
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - P.U.
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 50
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Services
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 52
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 53
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - VARTM
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 55
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Metrology
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 59
JEC COMPOSITES MAGAZINE - Issue #84 - October 2013 - 60
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