JEC COMPOSITES MAGAZINE - Special Issue Composites for mobility - May 2020 - 15

The future of mobility is linked to the development of composite materials

with metals, recyclability and manufacturing efficiencies for automakers," Krull
said. "In addition, composite solutions
offer the ability to integrate components
and functionality, leading to cost efficiencies coupled with mass reduction. From

an OEM perspective, certain composite
solutions enable modularity, which can
help our customers manage complexity
within their own manufacturing processes."
Füller concluded, "Our strategy is to

use the right material at the right place.
This means it is finally a decision driven
by the function and cost of the material.
In the last year, sustainability has gained
more importance in the whole material
selection process."

lnterview
JCM: Do you see potential for bioplastics and biocomposites in the
automotive industry?
David Grewell: Yes. Ford has already adopted them. Some time ago,
Ford began using soy-based foams for
seating applications. In fact, Deborah
Mielewski, Ford's senior technical
leader for sustainable materials and
one of our board members, will tell
you there are over 32,000 soybeans in
every one of the cars they manufacture
in the United States. Ford also is collaborating with McDonald's to use coffee
chaff in a thermoplastic biocomposite for headlamp housings. Another
automotive application involved CB2
members Ford and RheTech, and a
former member, Diageo, one of the
world's largest distillers. RheTech is
a provider of polypropylene compounds, engineered resins, colour
concentrates and additives. After the
production of tequila, Diageo had a
lot of leftover agave fibres. They were
considered a waste stream at the time,
and they would have to get rid of it.
We developed a technology whereby
RheTech could cost effectively com-

An interview with David Grewell, Ph.D., director, Center
for Bioplastics and Biocomposites (CB2), and department chair and professor, Department of Industrial
and Manufacturing Engineering, North Dakota State
University
The Center for Bioplastics and Biocomposites (CB2) is a National
Science Foundation Industry and University Cooperative Research
Center. The centre focuses on developing high-value bio-based products from agricultural and forestry feedstocks. Its members include
executives from more than 25 corporations and faculty of four U.S.
universities. JEC Composites Magazine asked director David Grewell
about progress in biocomposite use in the automotive industry. Ford
and Hyundai are CB2 members.
pound these agave fibres with plastics.
Then Ford uses this material to make a
part for an air-conditioning and heating application. The agave biocomposite is lighter weight, easier to produce
and consumes less energy to make
than the precursor material.
That's very interesting. Could you
share a little more about this agave-based biocomposite component?
D.G.: It is a rigid component used in
the mounting mechanism inside the

Fig. 4: Deborah
Mielewski, Ph.D.,
Ford senior technical
leader for sustainable
materials, uses
coffee chaff waste
from the McDonald's
supply chain to make
a thermoplastic
biocomposite at the
Ford Research and
Innovation Center

SPECIAL ISSUE Mobility / May 2020

heating and air conditioning system,
located behind the dashboard. This
thermoplastic injection-moulded part
is about 30.48 cm long, 10.16 cm tall
and 2.54 cm thick.
Do you see any applications for
biocomposites in other transportation modes, such as commuter rail
and subways?
D.G.: I see opportunities for biocomposites to be used anywhere across the
transportation industry.
You mentioned the use of coffee
chaff and agave fibres to make biocomposites. What other biocomposite materials are generating interest for automotive applications?
D.G.: A lot of people are looking at
the leftovers from coffee production
as well as hemp fibres, bamboo fibres
and even cotton. There are many materials being considered. All these
fibres can be used to enhance the
thermomechanical properties of plastics, whether it is strengthening them
or making them stiffer or whatever it
might be.

/ jec composites magazine

JEC COMPOSITES MAGAZINE - Special Issue Composites for mobility - May 2020

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