JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 36

AUTOMOTIVE
reinforcements

Carbon multiaxial fabrics
for safety-critical application
Bright Lite Structures selected Hexcel's HiMax™ reinforcements for the
manufacture of safety-critical areas of the Zenos E10 composite chassis. The
carbon fibre multiaxial fabrics ensure that the sports car s oor structure can
withstand seat belt pull-out loads in the event of a crash.
ANTONY DODWORTH
Chief Technology & Manufacturing
Officer and Managing Director
Bright Lite Structures
&
DAN NORTON
NCF Sales Engineer - Automotive
Hexcel Reinforcements UK

B

ritish company Zenos Cars was
established in 2012 by a group of
experienced car industry professionals. The team's aim was to develop a
high-performance sports car with low
ownership costs, making an exhilarating
driving experience accessible to larger
numbers of people. The lightweight, innovative composite construction of the
cars delivers exceptional performance and
driver experience on both road and track
at purchase prices starting from approximately £27,000.
Zenos started the production of its first car,
the E10, in January 2015. Equipped with
a mid-mounted 200 bhp 2-litre engine,
the E10 accelerates from 0-60 mph in just
4.5 seconds and boasts a top speed of 135
mph. Today, there are two further models
in the Zenos range - the 250 bhp turbocharged E10 S and the 350 bhp E10 R. A
wide range of options mean each customer
can select the look and performance they
want. The cars are 100% British-designed
and British-built and are currently sold in
Europe, the USA and China.

36

A fresh approach
As a young company with enormous expertise in both the motorsports and mainstream automotive arenas, Zenos prides itself on its ability to approach car design and
manufacture in new and innovative ways.
With the objective of reducing component,
tooling and assembly costs (to make the car
more affordable), whilst keeping car weight
down to optimise speed and handling, it
was decided to use composites in the car's
structural assemblies as well as the body
panels. The inexpensive glass fibre-reinforced vinyl ester composite body panels
are easily replaced in the event of damage.
The hybrid carbon fibre composite and aluminium chassis is extremely lightweight,
strong and stiff, and recycled carbon fibre

Fig. 1: The Zenos E10
boasts a top speed of 135
mph. High levels of grip
are matched to predictable
handling and superb ride
quality, courtesy of an allround double-wishbone
suspension attached to a
stiff aluminium spine

jec composites magazine / No110 January - February 2017

is incorporated to increase strength and
reduce cost.
The Zenos E10 chassis was designed
and developed by Bright Lite Structures,
which has patented a unique, low-cost
manufacturing technology for carbon
composite components. The company's
design philosophy for this project was
to make the chassis as simple, attractive
and low cost as possible, whilst maintaining its high functionality by maximising
parts consolidation and integrating assembly features. Unlike many other vehicles, the chassis is not hidden beneath
body panels, which reduces part count
and cost. It is also designed to "clip" together tongue-and-groove style, prior to



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017

Cover
Edito
Opinion: Mobility
Contents
NEWS
In brief
Startup competition
Construction & public transport
Investment
Agenda
BUSINESS
Trend
Startup booster
China
MANUFACTURING
RTM
WPC
Sandwich
Feature Automotive - El dorado, or a lure
3D printing
Cycle time
Raw materials
Reinforcements
Compression moulding
Compression moulding
Lightweighting
Interior part
SOLUTIONS
Marine
Motorcycle
Medical
In the world
TECHNOLOGY
OPLC
Draping
Damping
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 60
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Opinion: Mobility
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Startup competition
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 11
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Construction & public transport
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Investment
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 17
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Trend
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 19
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Startup booster
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - China
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - RTM
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 24
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - WPC
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Sandwich
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 3D printing
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 29
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Cycle time
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 31
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Raw materials
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 35
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Reinforcements
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 37
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Compression moulding
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Compression moulding
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Lightweighting
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 41
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Interior part
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Marine
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 44
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Motorcycle
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Medical
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - In the world
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - OPLC
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 49
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 50
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 51
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 52
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 53
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Draping
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 55
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Damping
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 57
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 59
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