1 Technology Highlights - Faurecia · Faurecia Technology Highlights 4 2011 Frankfurt Motor Show ventilation components into decorative parts, notably through clever use of dimpled

Press Kit

1

2011 Frankfurt Motor Show

Technology Highlights

Automotive Seating ......................................................... 3Complete seatsNew generation seat mechanismsSeat structuresMechatronicsComfort systemsTrim systems

Interior Systems ............................................................. 8Decorated partsDoor panelsAcousticsGreen & lightweight

Emissions Control Technologies .................................... 11Faurecia ASDSBMW M3 complete exhaust line Complete compact exhaust systemTurbo-manifold and close-coupled converterInduction brazingHydroformingAudi Q7 liquid SCR emissions control line

Automotive Exteriors ...................................................... 13Bumpers core businessComplete product range

Notes ............................................................................... 16

About Faurecia ................................................................ 19

Contacts .......................................................................... 19

Contents

3Faurecia Technology Highlights


Performance Seat

Performance Seat targets entry-level to mid-range vehicles in the European and North American markets. Drawing on approaches used in sportswear and fashion, it uses design as a central feature to convey the concept of performance.

The seat is made even lighter through the use of plastic components, which literally cover the whole seat (including plastic seatback and plastic cushion module). Compared with conventional seat systems, Performance Seat solutions represent a weight saving of some 20%. The innovation also provides a more spacious interior.

Performance Seat goes back to basics, turning core components into fully fledged style features: the seat structure is visible, incorporating an active suspension system; the cover carving offers a whole range of textile customization options. «We wanted to optimize every aspect of seat functionality. Our goal was to incorporate as many additional features as possible into the seat structure itself,» explains Mr Wlasak. Each seat also has its own audio module, allowing individual occupants to create their own comfort zone.

Performance Seat uses design features to put technology firmly center stage, with Faurecia innovations clearly in the spotlight.

Premium Seat

Premium Seat is the second hallmark of Faurecia’s campaign to reinvent automotive seating, and is designed for the premium market. Andreas Wlasak: «Our engineers and designers drew inspiration from the world of luxury watches: flawless detail, use of cutting-edge technology and reliability are three concepts specific to the luxury industry that also reflect Faurecia values.»

Technology (multi-media functionality, speakers built into headsets and welcome lighting), finishing quality (high-precision cut & sew, dimpled leather, metallic finish and wood paneling), and comfort (adjustment fea-tures and thermal comfort) are the three watchwords of Premium Seat solutions.

Echoing creations from the workshops of the finest watchmakers, Premium Seat technology turns

Automotive Seating

Complete seats

World number one in seat frames and mechanisms, and number three in complete seat systems, Faurecia unveils two seat prototypes in Frankfurt that are bound to turn heads among industry professionals and the general public: «Performance Seat» and «Premium Seat» both reflect breakthrough technology buoyed by stunning design.

Faurecia Automotive Seating recently caused a sensation with SmartFit™, an application for smartphones that allows passengers to use their mobile device to identify and activate the most ergonomic settings based on their physical profile. The world’s sixth-largest automotive equipment supplier has now taken things even further with its Performance Seat and Premium Seat solutions—two prototypes that draw on the cream of seat technology and design from Faurecia experts. Faurecia Design Director Andreas Wlasak: «These two prototypes reflect a daring creative departure in which the design is used to showcase performance, perceived quality and technology; not hide it.»



ventilation components into decorative parts, notably through clever use of dimpled leather. Air vents are positioned all around the seat, thereby enhancing overall air conditioning. The innovation also marks a world first with the use of shagreen in automotive seating. The firm, flexible covering—commonly used by cabinetmakers and leatherworkers—further enhances the seat’s premium feel, making it a jewel in the interior crown.

Plastic, wood and aluminum come together to create a resolutely high-end seat. Here, Faurecia displays the use of Ligneos technology, which makes it possible to work in 3D with large sheets of wood (mainly oak and maple) to make them lighter and more flexible, offering the benefits of hand-made craftsmanship on an industrial scale. The approach also conveys the true beauty of wood trim, with the option to use five species of real wood.

The back of the headrest incorporates a complete multimedia setup (screen, internet connectivity, etc.), providing a comprehensive set of controls in a custom environment. The side of the seat also features blue welcome lighting, providing the perfect backdrop for the on-board technology.

SmartFit™ phone-activated seat adjustment system

Based on the acclaimed Audi A8 premium seats, Faurecia has developed a new concept for automated seat positioning that takes the guesswork out of properly adjusting seats. SmartFit™ is an application for smartphones that automatically adjusts the vehicle’s seats to conform to the healthiest position for each occupant, controlling the seat wirelessly.

SmartFit™ initially guides the user through an easy-to-follow process for creating a digital model of his or her body. This virtual model is combined with advanced anthropomorphic data to calculate the perfect seat settings. This tailored fit then is sent wirelessly from the cloud to the phone to the seat, which automatically adjusts itself. Individually tailored profiles can be generated for each occupant and stored in seat memory.

SmartFit™ reduces seat complexity by optimizing the user interface to the traditional seat electronics, using a device that occupants bring into their vehicles every day. Moreover, eliminating redundant components is an effective approach to reducing vehicle mass and chemical-based materials.

In addition to its environmentally-friendly attributes, SmartFit™ supports healthy posture for drivers. Globally, people are increasingly prioritizing a healthy lifestyle. SmartFit™ supports the consumer’s desire for both improved wellness and mobile connectivity by creating a seat-tailoring system designed by ergonomic experts. It improves overall comfort, thereby reducing potential distractions that might otherwise result from drivers’ repeatedly readjusting their seat to find a comfortable position. Never before has a seat provided this level of guided adjustability that ensures occupants take full advantage of advanced comfort systems. As a result, automakers that incorporate SmartFit™ into their vehicles may enjoy considerably improved customer satisfaction scores relating to seat comfort. No longer do consumers find themselves confused by a multiplicity of seat controls; nor do they need to struggle as they drive to determine the best adjustment for their body. SmartFit™ adjusts seats to the best fit automatically.

Faurecia’s integration of Hoerbiger’s seat comfort segment, which specializes in the development of leading-edge pneumatic seat comfort systems, allows for a wide variety of comfort functions, such as massage, shoulder, lumbar, lateral and thigh support. Over time, lighter and thinner pneumatic systems are expected to substitute for existing electro-mechanical systems across vehicle segments. Obviously, SmartFit™ will greatly benefit from the integration of pneumatic systems, largely thanks to easier seat comfort adjustments.

Faurecia foresees strong interest in the SmartFit™ concept and anticipates that it will be ready for vehicles in model year 2014 or 2015.



New generation seat mechanisms

Nano height adjusterRD7X discontinuous reclinerRC7X continuous recliner

These three new generations of Faurecia seat mechanisms, currently under development, are suitable for vehicles from segments A to F, focus on weight and packaging reduction. These mechanisms have a high dynamic breaking torque, are light weight (up to 35% versus current products) and more compact (up to 18% in diameter and up to 25% in thickness). They offer weight savings of up to 300g per seat and better perceived quality and a smoother operation. Faurecia will manufacture these mechanisms from 2012.

Ultima Seat Tracks

The Faurecia Ultima seat tracks represent the new generation of high performance seat tracks, specially designed for high-end and premium vehicles. They exist in manual and low-noise powered versions for 3- and 5-door vehicles. Thanks to the use ultra high strength steel, proprietary to Faurecia, it has been possible to enhance energy dissipation in the case of a crash by up to +20%, versus current products. In all, the Ultima tracks provide best-in-class safety, lightweight and perceived quality. Faurecia will start manufacturing these tracks from 2012.



Seat structures

Composite backrestA plastic front seat backrest made of high-strength composite material, enabling design freedom on seat backrest for new premium interior styling.

In partnership with BASF, Faurecia has developed an ingenious composite seatback that creates an all-new aesthetic and eliminates conventional metal frames, heavy foam and trim covers in favor of materials that produce a lighter, thinner and cleaner seatback. Over the past three years, BASF has focused on enhancing the material’s scientific performance aspect, while Faurecia has designed, validated and integrated the seatback system and architecture into a new first-row seating concept for the industry. The composite seatback is ready to make a significant difference inside vehicles that will be launched in the coming years.

The combined first-row composite seatbacks:• Weigh almost 20% less than conventional seatbacks, reducing CO2 emissions over the life of the vehicle by an estimated 100 kilograms;• Are 15% thinner than the industry’s thinnest seats, leading to 10 liters of additional interior cabin volume.

The lighter weight can yield improved fuel performance for internal combustion, hybrid and all-electric vehicles; and less fuel consumption means fewer emissions of greenhouse gases. At the same time, the significantly thinner seatbacks allow designers either to provide more leg room to the second-row occupants or to shorten the overall length of the vehicle, thereby further reducing its total weight. The seatback is a technically mature system that has been fully validated for reliability, safety and comfort. Designers now have entirely new opportunities to customize and adapt seatbacks in vehicles. Since they are created with injection molding systems, the composite seatbacks allow

for novel shapes and accessories to be added for the comfort of front seat occupants and the convenience of second-row passengers. This seatback currently is in advanced development with Asian and European automakers and has also seen significant interest from North American manufacturers who are looking to benefit from its thin and lighter-weight structure. In preproduction programs, Faurecia is furthering the technological maturity and integration of the composite seatback by incorporating it into the new generation of seating systems. Consumers could begin enjoying the benefits of the composite seatback on 2014 vehicle models.

Mechatronics

E-pumpTraditionally, seat height adjustment was performed manually; however this function is now ever more performed electrically. For this purpose, Faurecia has developed the E-pump, a powered “seat pump” for seat height adjustment incl. mechatronics for the best postural adjustment in a lighter and more compact part. The lightweight development has enabled to save 25% weight for this function versus traditional linear actuators. Also, the global packaging has been reduced both in diameter (-14%) and length (-30%) versus existing 2 pole motors. Furthermore, compatible with Faurecia’s Nano seat mechanism (see above), E-pump specifically targeted at C to E segment vehicles, is expected to go into series production later this year.



Comfort systems

MHH (Multi Horizontal Hardness)A new foam pad, i.e. with reduced cushion height providing the same comfort level as a standard foam pad, particularly for low-roof vehicles.This new foam for seat cushion has been designed for both front and rear seats, particularly for low-roof vehicles. It replaces the cut foam gluing process with a “light” compression process while offering enhanced comfort levels and also offers a new comfort approach for seat bolsters. The process consists in spraying several polyurethane formulas in two-steps before final compression. Not only is the foam thinner, it is also up to 20% lighter than traditional foam pads.

Pneumatic SystemsFor ultimate driver and passenger(s) comfort: the ultimate solution for premium best-in-class postural comfort.

With the acquisition of Hoerbiger’s Automotive Comfort Systems activity at the end of 2010, Faurecia has taken the lead in active seat comfort systems. Its proven track record ranges from Audi A8 and A6, to BMW 7 Series and Mercedes-Benz S-Class and the new M-Class to name but a few. Pneumatic (vs. electro-mechanical) seat comfort systems, mainly targeted at premium vehicle segments, allow for a wide variety of comfort functions, such as massage, shoulder, lumbar, lateral and thigh support.

In addition, the pneumatic systems can be adjusted individually to the contour of the driver/passenger, resulting in ergonomically first-class vehicle seats using the sophisticated system. This is already the standard in the latest high-end German “premium” vehicles. Over time, lighter and thinner pneumatic systems are expected to substitute existing electro-mechanical systems across vehicle segments. Furthermore, the pneumatic seat systems developed by Faurecia and the components installed in the seat systems are covered by a comprehensive portfolio of patents, ensuring long-term technology leadership.

Faurecia pneumatic seat systems exist is several configurations from 4 to 8-way, offering the complete range of lumbar support and comfort adjustments as well as massage functions for backrest width, cushion width, cushion length and shoulder adjustment. The system uses a series of highly discrete, lightweight (< 1kg/seat) TPU [thermoplastic polyurethane] inflatable bladders, which can be individually controlled. These variants enable to propose the most advanced premium seating features for top of the range comfort and back pain relief offering exclusive comfort features.

At the IAA this year, Faurecia’s pneumatic seating systems can be found on the following newly introduced vehicles (standard or optional): Audi A6 Avant and Mercedes-Benz M-Class.

Trim systems

X-locking headrestA 4-way front headrest with side button for user friendly adjustment and increased safety and comfort.

The 4-way X-locking headrest is an ideal replacement for active or reactive headrests, offering more value for a lighter weight. The easy unlocking is performed via a simple side button, while the front part adjustment range can reach up to 25 mm. For C to E segment vehicles, this solution offers the best compromise between comfort and safety and can also be tailored to fit the vehicle’s styling with rear shell finish. This headrest will go into series production in 2012.



Decorated parts

Volkswagen New Beetle IP (including interior decoration using either high gloss paint or film.)For this revamped icon, Faurecia has developed and manufactures the complete instrument panel, incl. glove box, air vents and IP deco trims (paint, film). The so-called “Dash Pad” is a wink to the original Beetle without being retro. In Europe this dash pad is painted a high gloss black on the “Beetle” trim, in the car body color in the “Design” trim, whereas the high-end “Sport” trim features a very dynamic carbon fiber look (film). As in the original Beetle, the new Beetle boasts an extra glove box (the “Beetle” box) integrated into the dash pad on the passenger side. Its lid opens upward, while the standard glove box –situated in the lower part of the instrument panel– opens downward.

Volkswagen New Passat IP (including aluminum trim.)The Instrument Panel of the Volkswagen Passat has been developed and is manufactured by Faurecia. The top cover skin is made of sprayed polyurethane, i.e. without PVC, thus reducing volatile organic compounds (VOC) emissions inside the vehicle. The top cover structure is made of styrenics with Glass Fibers (ABS/PC – GF13). The instrument panel structure integrates air duct in styrenics (ABS/PC) and shot channel (in two different versions: with/without diffuse ventilation). In

terms of decoration trim, the technology used is brushed aluminum, signed Faurecia Angell-Demmel, or real wood appliqué. The touch and feel of the aluminum trims of the IP, center console and door panels convey a particularly refined atmosphere. The overall result is a high level of perceived quality which conveys a premium-feel. Thanks to the integration of a soft seamless airbag it ensures a safer airbag deployment.

Interior SystemsMercedes-Benz SLK IP/CC (slush IP including center stack featuring aluminum decoration parts)

Faurecia supplies the slush instrument panel for the new Mercedes-Benz SLK, further enhancing the car’s high-end style. The sports luxury embodied by the SLK interior is underscored by the addition of brushed-aluminum trim. This high-end material showcases ‘hand-made’ expertise and comes as standard. The color display and entertainment features are housed in the center of the dashboard. The top of the dash also features an analog clock, an unusual detail that subtly underscores the roadster’s refinement. This area of expertise is the work of Angell-Demmel, the world’s leading manufacturer of aluminum trim for automotive interiors, acquired by Faurecia in January 2011. The move reflects Faurecia’s determination to strengthen its ties with German customers in the premium segment, including Daimler, while enhancing its range of products and technologies for automotive interiors.

Ford Focus complete cockpit: featuring material harmony & decoration parts.

In designing features such as the cockpit-style instrument panel, Faurecia has brought a number of improvements to the compact-yet-functional car. The integrated Reinforced Airbag Lid Foamed (RALF) concept completely masks the airbag flap while ensuring optimal deployment in the event of an accident. The wraparound center console gives easy access to the key onboard controls and displays. Drawing on the collaborative efforts of a number of international names, the Focus is breaking new ground in the global market, setting new standards in driving comfort and design: the modern feel of the car’s interior and its impressive finishing help give occupants the feeling that they are travelling in a premium-class sedan. Assembled at SAS (a Faurecia &



Continental JV) in Saarlouis (Germany), the Ford Focus cockpit offers outstanding fit and finish, integration of decorative trims, a harmonious blend between upper and lower parts and invisible mechanical components (with no visible screws). Faurecia technology has brought the new Ford Focus to the next level in perceived quality.

Door panels

Cadillac SRX door panel: a premium reference incl. cut & sew armrest and localized foam.For the Cadillac SRX midsize premium SUV, Faurecia has developed the front and rear door panels. The top roll and inserts feature a cut & sew hand wrapping with artificial leather, the armrest, including local foam, is made of a molded collapsible substrate hand wrapped with polyurethane. The door panel lower carrier is made of injection molded TPO (thermo polyolefin), while real wood appliqué rounds up the premium feeling. Finally, the door panel also features a puddle light while ambient lighting is optional. With robust yet fine materials, Faurecia offers a high level of perceived quality and a specific attention to detail and high-end finish. The door panels offer a soft treatment and excellent haptic and grain quality on the main touch surfaces, highlighted by the use of authentic wrapping, high quality materials offering also a quiet ride.

Citroën DS5 door panel: a premium reference incl. cut & sew armrest and door liner.

Contributing both to style and interior elegance, the Citroën DS5 door panels are perfectly integrated into the refined and attractive interior where surprise and seduction dominate. They reflect the attention to detail, both in the choice of material (color and trim) – for example with the « Club » smooth full grain leather – as well as in the fit and finish perceived quality. The expertise and craftsmanship of Faurecia designers and engineering teams can be seen in the attention paid to seams and the matching cut-and-sew leather, plastic and aluminum of the door handle. Faurecia has been able to offer a modern interpretation of what Premium means.

Aluminum decorationFull range of aluminum decoration parts on a totem presenting a variety of decorations to reach several effects and patterns for tailored or bespoke solutions.

Acoustics

Citroën C6 package tray

The Citroën C6 premium sedan boasts a lightweight package tray using a compression molded carrier made out of extruded polypropylene filled with woodstock, offering both high perceived quality and recyclability.



Molded floor carpet

The structural floor developed by Faurecia replaces steel, injected plastic or composite floors. It is made of a twin wall Sommold glass fiber polypropylene mat, offering high load resistance and as well as functional integration of air ducts, storage boxes, air grids, attachment features and acoustic insulation.

A lightweight material that Faurecia has developed for the rear shelf of cars has now been adapted for flooring of multipurpose vehicles (MPVs), as well. Sommold is a glassfiber-reinforced polypropylene material that Faurecia has designed for package trays that need no welded pivots for rotation. The Sommold option reduces costs and diminishes weight by as much as 50 percent compared to traditional materials. Faurecia has advanced its Sommold technology to produce a complete structural floor that can replace heavier flooring materials in vehicle trunks and in the second and third rows of MPVs. The new flooring includes structural and carpeting components and allows for the integration of air ducts between the two sheets of the Sommold floor to cool or heat the rear portions of the vehicle. In addition to saving as much as 5 to 7 kg per vehicle, nearly 100% of the Sommold floor is produced using recycled materials, and the material offers high levels of acoustics dampening, making it an exceptionally environmentally friendly Faurecia product.

Green & lightweight

Smart fortwo IP (flax / polypropylene)

The instrument panel consists in equal proportions of a substrate which contains compressed flax fibers and polypropylene. It is pleasant to the touch, particularly the fabric-covered soft surface on the top cover, and provides weight savings of 15% when compared to traditional solutions. Other advantages include excellent impact / crash performance.

BioMat (100% bio-sourced composite material)

Over the last three years, Faurecia has been working on the development of bio-sourced “plastic” to replace traditional oil-based plastics used for automotive interior parts. BioMat is the result of Faurecia’s innovation process, now ready for commercial deployment, first for non-visible interior parts.



Emissions Control TechnologiesFaurecia ASDSAnticipating ever more stringent international emissions legislation on Nitrogen Oxide (NOx) across all regions of the world, Faurecia, the world leader in emissions control technologies, is presenting the Faurecia ASDS (Ammonia Storage and Delivery System), its breakthrough NOx reduction technology for Diesel engines. The Faurecia ASDS is a pure ammonia Selective Catalytic Reduction (SCR) system – as an alternative to liquid SCR systems– which delivers very precise amounts of ammonia to a catalyst in the exhaust line. This step enables highly efficient removal of NOx from Diesel engine exhaust gases for both passenger cars and commercial vehicles. Faurecia is confident that this technology will offer significant advantages to automakers when meeting Euro 6, Tier 2 Bin 5 and future Euro 7, Tier 2 Bin 2 emissions regulations for Diesel NOx reduction. For more information, see separate Case Study on Faurecia ASDS.

BMW M3 Complete exhaust Line

Faurecia developed and manufactures in Augsburg, Germany the full gasoline exhaust line for the sports vehicle BMW M3 4.0-litre V8 engine.

The complete line consists of:• dual fabricated manifold with a “4 in 1” geometry;• four different catalytic converters (two in close-coupled position, two in under-floor position) with oval section;• hydroformed pipes (diameter 65mm) with a heat • shield to protect surrounding components;• transverse rear muffler with four tail pipes;

Faurecia is the exclusive supplier of the full exhaust system (manifold / hot-end / cold-end) to this premium sports vehicle. The line offers lower backpressure to allow high performance of the engine at full load and brings superior acoustics to match the customer’s brand requirements. It also fulfills European Euro 5 emissions regulation.

Complete compact exhaust system (for “Range Extender”)

Today, electric vehicles have limited autonomy due to the capacity of current state-of-the-art batteries. Therefore many electric vehicles will use a range extender – a small and optimized internal combustion engine - to recharge the vehicle’s batteries and improve the overall driving range. The exhaust system for such a range extender engine poses new challenges for emissions control, acoustics and packaging.

Faurecia introduces its prototype range extender exhaust system designed for a two-cylinder gasoline engine. This consists of:• a maniverter, or combined manifold and catalytic converter, which collects exhaust gases and eliminates the three main pollutants (HC, CO, NO). The catalytic converter efficiency is enhanced thanks to its close-coupled position;• two mufflers: a main muffler and a small resonator, using long, ultra thin-wall pipes (0.8 mm) for efficient low-frequency attenuation.

As an optional component, Faurecia’s EHRS (Exhaust Heat Recovery System) can be fitted to the range extender exhaust system. The EHRS uses waste exhaust heat to warm up the passenger cabin and ensure optimal engine warm-up at cold start and hence improve fuel consumption.

Other optional equipment includes electric acoustic or adaptive valves, which may be fitted to the system to reduce the size of the main muffler, thereby reducing the mass and size of the exhaust system, while improving the overall acoustics of the vehicle..



Turbo-manifold and close-coupled converter (for BMW 2.0 liter gasoline twin turbo engine, 245hp)

The Faurecia lightweight air gap insulated twin scroll manifold and close-coupled converter offers more torque and more power, combined with lower fuel consumption, to this state of the art engine. The twin scroll configuration allows for the optimized combina-tion of low-speed response and high-end power. The fabricated manifold, 20% lighter than a cast alterna-tive, uses hydro-formed pipes and withstands gas temperatures of up to 980° C, allowing for high-per-formance driving.

Induction brazing

Faurecia Faurecia’s advanced process technologies for exhaust products now includes induction brazing. Brazing is a metal-joining process whereby a filler metal is heated and distributed between two or more

close-fitting parts by capillary action. It is similar to soldering, except the temperatures used to melt the filler metal can go up to 1,000°C. The heating occurs as a result of the resistance to the flow of current induced by conductive materials when placed in a magnetic field produced by a high frequency.

In the automotive industry, this technology is unique for complete exhaust systems. It brings advantages of reduced weight by enabling the use of thinner materials (0.6mm) which cannot be joined by welding. It also delivers higher quality, as it is spatter free and without distortion, and better durability than a line using welded joints

Brazing is particularly well adapted for complete hot and cold-ends, manifolds and tailored tubes. Faurecia has proven this technology for various products and is already in production on: fuel vaporizer (Ford); tailored thin-wall tubes (Audi Q7, Mercedes-Benz S-Class and Porsche Panamera); high-performance manifold flanges (BMW M3). Faurecia will start production of a fully brazed cold-end exhaust system in early 2012.

Hydroforming

Another process technology used by Faurecia for its exhaust business is “hydroforming”. Hydroforming is a state-of-the-art manufacturing process, already widely used for tubes and manifolds. The principle is to inflate a tubular part inside a tool by a pressurized liquid, in order to give it a pre-defined shape. This technology is now being used by Faurecia for muffler shells to provide a perfect underbody fit, as non-cylindrical shapes can be obtained at the same cost as cylindrical shapes. It also allows more design freedom to make oblique inlets or outlets, and to use variable wall thicknesses (for example 1mm at inlet/outlet and 0.6mm in the center muffler section) thus reducing overall mass. As a general rule this technology is less costly than a stamped muffler of similar internal volume. After passing all necessary Faurecia testing phases, this technology is currently being promoted with several major automakers.

Audi Q7 liquid SCR emissions control line

Supported by the acquisition of EMCON Technologies and its expertise in diesel systems for passenger cars, Faurecia has become a major supplier of selective catalytic reduction (SCR) technology for clean-diesel vehicles. The SCR reduces nitrogen oxide (NOx) pollutants by using ammonia as a reductant to convert the NOx into nitrogen, water and carbon dioxide (CO2). Faurecia’s SCR system can slash NOx emissions by 90% while preserving the fuel economy and operational benefits of diesel engines. This technology has been adopted by many producers of cars and light trucks over the past three years and is recognized by engine manufacturers as the preferred diesel emissions-control technology for complying with the US EPA’s NOx standards since 2009 and the future European 2014 Euro6 NOx standards.



Automotive Exteriors

Bumpers core business

Audi A6 bumpers

The front and rear bumpers made by Faurecia reflect the perceived quality expected of Germany’s leading automaker in the premium segment. Faurecia also poured its ample expertise in the field: a painting pro-cess ensuring a faultless paint stretch, a management of fit and finish in line with the premium requirements of Audi, as well as a perfect integration on the front with the large and low Singleframe grill, featuring be-velled upper corners.

BMW M5 front bumper

Faurecia has developed and supplies complete front & rear bumpers reflecting the high-level of fit and finish for the M5 specific sports exterior parts. The design of the front bumper clearly embodies the supreme power of the new V8 engine. The wide-spread arrangement of the customary M black slats – like the three air intakes in the lower section of the front apron – emphasize the cooling air requirement of the engine behind the grille. The arrangement of the air intakes over various levels

creates an impressive depth which underlines the dy-namic, forward-thrusting appearance of the Saloon. The two side air intakes, meanwhile, have a dynami-cally curving form. Positioned far to the outer edges of the car, they emphasize its wide track and fill the spaces in the front apron, normally reserved for the fo-glamps in the BMW 5 Series Sedan. At the lower edge of the front end, air-channeling flaps developed on the race track ensure optimized aerodynamics. The main

advantages of Faurecia’s bumpers are perceived qua-lity, better gap & flush, precise color and gloss mat-ching, and resistance to minor bumps.

Citroën DS3 front bumper

In addition to its distinctive and versatile design, the DS3 is packed with Faurecia expertise to protect pedes-trians, including Faurecia’s patented metal-polypropy-lene hybrid front-end carrier, which provides excellent absorption. As on the Citroën C3, the bumper incor-porates a panel strengthener and “compliant” system that ensures a tight fit and finish between parts. With its sculpted style and distinctive looks, the DS3 is a real head-turner, not least because of the LED-based Day-time Running Lights (DRL) tucked into the front end, which create a dynamic feel suggesting a fresh driving experience, and allow the vehicle to comply with the new regulations, undeniably a design asset.

Ford C-Max

The front and rear bumpers for the Ford C-Max and Grand C-Max made by Faurecia in Spain, reflect the Kinetic Design that Ford has successfully deployed across its vehicle range. With its dynamic front and rear-end styling, clean lines and superb trapezoid grille, the Ford C-Max has a decisively contemporary look. Faurecia’s one-piece front bumper is on of the key elements of this look. The front-end has also been designed to offer better protection for pedestrians, with a reshaped fascia to help cushion the impact. Not to be outdone, the rear bumper is fully at home in this sporty environment.



Mercedes-Benz SLS AMG front bumper

The Mercedes-Benz SLS AMG front bumper enginee-red and developed by Faurecia, reflects the high-end sports positioning of the vehicle. The bumper is pain-ted using so-called “flat paint” a new painting process which gives vehicles a new excusive and less shiny and glossy aspect. Faurecia’s expertise in making bumpers with complex geometry parts is applied to the SLS bumpers using mat varnish. The advantages are a hi-ghly visual attraction, perfect fit-and-finish and unique customization.

The color charts for the Mercedes-Benz SLS AMG include nine exclusive paint finishes. The highlight comes in the shape of the unique «AMG ALU-BEAM silver» paintwork: the new, unique process makes the paint shine like liquid metal. The paint covers the body panels like a metallic skin, emphasizes the scintilla-ting design lines of the ‘Gullwing’ more strongly than any previous paint job and makes them even livelier by means of targeted light reflections. This effect is made possible thanks to tiny pigments measuring between 30 and 50 nanometers. The two matt finishes «designo magno allanite grey» and «AMG magno sylvanite grey» are just as eye-catching: with their matt silk surface they reinforce the sporty character of the two-seater through specific contouring of the crease lines.

Renault Kangoo Be Bop

The front bumper of the Renault Kangoo BeBop is a specific two-tone version, where Faurecia is in charge of the injection process, painting and final assembly. Esthetically, this bumper features a two-one aspect: in body color for the fascia and in platinum grey for the central so-called “plastron” part, which bears the li-cense plate. Faurecia has a proven track record in ma-naging the complete manufacturing of a high diversity of finished products for the same vehicle.

Complete product range

Front & rear bumpers: Audi A6

Faurecia is producing both the bumpers (front & rear) and rocker panels of the Audi A7 from its plant in Pappenheim, Germany. They meet the high per-ceived quality standards demanded by the German premium segment leader. Faurecia also poured its ample expertise in the field: a painting process en-suring a faultless paint stretch, a management of fit and finish in line with the premium requirements of Audi, as well as a perfect integration on the front with the large and low Singleframe grill, featuring bevelled upper corners.

Front-end module: Audi A6

Faurecia supplies a complete front-end to Audi plants. Developed and patented by Faurecia, “mEasy” is a mechanical system that eases the assembly of this front-end on the vehicle directly on the OEM’s assembly line. Perceived quality is ensured by the “mEasy” arm which allows perfect fitting with the car body. This arm is in itself unique. Indeed, a final Z-shaped setting can be made at the last moment on the assembly line to adjust the headlight and bumper simultaneously to the hood. The module incorporates an array of functions such as cooling, and shock absorbers. The result: reinforced perceived quality, management of diversity and vehicle weight reduction. Supporting the front-end, the carrier displays a major innovation. Indeed, it is made of hybrid aluminum and polyamide. The goal of this carrier is to meet torsion constraints of the vehicle, constraints with hood locks as well as heat resistance. For the Audi A6, reaching only 2.8 kg on a carrier has been a real challenge that Faurecia’s product and process engineering has been able to meet.



Rocker panels: Mercedes-Benz SLS AMG

The Mercedes-Benz SLS AMG rocker panels (or side skirts) engineered and developed by Faurecia, reflect the high-end sports positioning of the vehicle. The side skirts are painted using so-called “flat paint” a new painting process which gives vehicles a new excusive and less shiny and glossy aspect. Faurecia’s expertise in making rocker panels with complex geometry parts is applied to the SLS bumpers using mat varnish. The advantages are a highly visual attraction, perfect fit-and-finish and unique customization.

The color charts for the Mercedes-Benz SLS AMG include nine exclusive paint finishes. The highlight comes in the shape of the unique «AMG ALU-BEAM silver» paintwork: the new, unique process makes the paint shine like liquid metal. The paint covers the body panels like a metallic skin, emphasizes the scintillating design lines of the ‘Gullwing’ more strongly than any previous paint job and makes them even livelier by means of targeted light reflections. This effect is made possible thanks to tiny pigments measuring between 30 and 50 nanometers. The two matt finishes «designo magno allanite grey» and «AMG magno sylvanite grey» are just as eye-catching: with their matt silk surface they reinforce the sporty character of the two-seater through specific contouring of the crease lines.

Liftgate: Ford Kuga

From grille to tailgate, Faurecia has invented new ways to envision automotive exterior systems and modules, reducing weight dramatically while simultaneously in-creasing convenience and safety for drivers, passen-gers and pedestrians. Faurecia has introduced clever new automotive exterior products with a sharp new focus on our principles of lighter weight, lower fuel consumption and customization to gain adaptability and design freedom.

Since the invention of the station wagon, the tailgate has raised images of a heavy, bulky, difficult-to-operate system. With its fully functional thermoplastic liftgate for the Ford Kuga, however, Faurecia has elevated ease of use and slashed the weight of the tailgate. Instead of being fashioned conventionally from steel, this first-of-its-kind tailgate is molded from thermoplastic, painted and equipped with foam inside the door for sound deadening. This breakthrough product reduces the weight of the liftgate by as much as 40 percent (7 kilograms). It also enables manufacturers to save as much as 70% on their tooling investment. Equally important, designers gain new freedom in shaping the liftgate to reflect the lines and individuality of each vehicle model. The system is capable of integrating all tailgate elements, including the rear window, spoiler, structures and panels. The Faurecia thermoplastic tailgate is currently in full production on the Ford Kuga crossover utility vehicle in Europe.



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FaureciaOlivier Le FriecMedia Relations Manager

+33 (0)1 72 36 72 58+33 (0)6 76 87 30 [email protected]

Crédits photos : Audi - BMW - Citroën - Daimler - Ford - GM - Renault - Volkswagen

Contacts

About FaureciaFor its first participation at the Frankfurt Motor Show since 1999, Faurecia – the world’s sixth largest automotive equipment supplier – will present its technology leadership in its four Business Groups: Automotive Seating, Emissions Control Technologies, Interior Systems and Automotive Exteriors. The Faurecia booth is located in Hall 5.1, Stand # B12.

achtung! GmbHMark JeznachConsultantStraßenbahnring 320251 HamburgTelefon: +49 40 45 02 10-1909Telefax: +49 40 45 02 [email protected]

www.faurecia.com/pressroommedia.faurecia.comww.faurecia-newsroom.de

http://media.faurecia.com

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Documents

1 Technology Highlights - Faurecia · Faurecia Technology Highlights 4 2011 Frankfurt Motor Show ventilation components into decorative parts, notably through clever use of dimpled