Since opening its doors in 2002, the Owens Corning Automotive Solutions Center in Novi, Michigan has quickly surpassed management expectations and helped broaden the use of composite materials in vehi…
Since opening its doors in 2002, the Owens Corning Automotive Solutions Center in Novi, Michigan has quickly surpassed management expectations and helped broaden the use of composite materials in vehicles. Charles Dana, president of Owens Corning“s composite solutions business unit, said the company“s automotive orders will rise 250% in 2004 compared with 2003. In the near future he sees automotive contracts accounting for USD 500 million in business, compared to “a couple hundred million” now. Owens Corning produces fiberglass for composite plastic materials used in parts such as end gates and mid gates, pickup beds, leaf springs, front-end and door modules, instrument panels and running boards. Composites are also used for tailgates, deck lids and hoods. Dana and Moe Lundrigan, vice president of Owens Corning Automotive, credit the Novi research and development center for promoting greater collaboration and a closer relationship with customers. “Every day we think how we can use 65 years of leadership in the glass and composites industry and convert it into possible (solutions) for automotive companies,” Dana said. The center is helping Owens Corning design and provide new materials for automakers to a shorter timescale. “This center was our attempt to create a clear and distinguishable presence in Detroit to make sure that we were positioned properly across the food chain and get our messages out,” Lundrigan said. Demand for composite materials is growing as auto makers continue the quest for lighter and stronger vehicles with quieter passenger cabins. “The key drivers for new vehicle programs revolve around cost reduction, fuel economy and weight reduction,” said David Andrea, vice president of new business development for the Troy-based Original Equipment Suppliers Association. Other applications for fiberglass include headliners, acoustic absorbers, flat-panel speakers, parcel shelves, door trim, hood and firewall liners and sunshades on the interior and exhaust silencer packing on the exterior. Although composites are more expensive than steel when molded to reduce the number of parts, they offer a number of benefits including lower overall cost, weight reduction, greater resistance to chemicals and heat, and durability. They also rattle less and offer more design flexibility. With the Novi center, Owens Corning continues to place engineering centers in vital areas in North America, Europe and Asia, while using local engineers and resources. “Because of our organization, we have the ability to address what“s being asked for from the auto industry from a global standpoint,” Lundrigan said. “What“s really important is having that relationship at the local level.” Automakers are demanding more accountable and accessible suppliers. “You want the responsiveness to the local market demand, but you want to respond to those needs from the aspect of global economies of scale,” said Andrea. Presently, an average vehicle contains 1.8 Kg of fiberglass. In the future, Dana estimates a typical car or truck could contain 90.7 Kg of the material. One application that is gaining ground is the composite pickup truck bed. General Motors, Ford Motor Co., Toyota Motor Corp. and Honda Motor Co. Ltd. will be producing trucks with composite beds in the next few years. “The OEMs believe that it will be the standard,” said Dana. The increase in electronic devices in vehicles, including navigation and audio/video systems, is also providing an opportunity for composites. “Everyone wants to have more and more electronics in their vehicles and it“s hard to put antennas behind steel panels,” Dana said.