Sapa Group - Shape Magazine 2007 # 1 - Aluminium / aluminum

8/14/2019 Sapa Group - Shape Magazine 2007 # 1 - Aluminium / aluminum

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SAPA + ALCOAA magazine from the Sapa Group 1 2007

AN EYEDESIGNER SIMON LAMARRE ON HISROLE WITH THE VOLVO C30.

Shape

FOR CARS

MEET OLE ENGER, SAPANEW PRESIDENT AND C

SLEEP SOUNDLY INA HSTENS BED

SAPA PROFILES LAUNCHHIGH-SPEED FERRY

SAPA + ALCOAREAD MORE IN SUPPLEMENT


2/24

have now been the President and CEO of Sapa

for six months, but my experience from the com-

pany is much longer. I have been on the board ofdirectors of Sapa since 2001 and during this period

I have gained a lot of experience about and developed

a positive attitude towards this fine and exciting com-

pany with so many possibilities.

The market situation for Sapa is good. During the

first part of the year, demand has continued to be

strong in most European markets, while the residential

and transport markets continued to be soft in the US.

Building System and Heat Transfer both experienced

good market development. We benefit from an upturn

in the economy and one of the largest challenges right

now is to utilise synergies and continue to improve our

results over the coming years.

Merging Sapas and Alcoas aluminium profileoperations has been an important challenge during my

first time in Sapa. The new company is presented in

the special insert in this issue of Shape, which will give

you a good view of the new Sapa; our future market

position and the special competencies and tailor-made

solutions that we will be able to offer customers all

over the world.

As a direction for the new Sapa, there are a few

values and guidelines that I wish to underline; I believe

in a decentralised business model where production

and our customers live in close intimacy. I also believe

in Genesis, our operational system, as the way we

work. This provides a way to build a corporate culture

and to create a shared platform and it helps us to see

the entire operation, from order to delivery, as a chain

of events in which we add value at every stage and

become an even better partner to our customers.

The new Sapa is a global leader in the aluminium

extrusion business. Building on the combined diversity

and strengths of Sapa

and Alcoa is how we will

shape the new future.

A flourishing future

I

CONTENTS

One-stop shop in PolandComplete products represent the future for Sapa Aluminium in Trzcianka.

SHAPE # 1 007

Sapa is an international business group that

develops, manufactures and markets value-added

aluminium profiles, profile-based components and

systems and heat exchanger strips in aluminium.

Sapa has annual sales of approximately SEK 19

billion and employs around 9,000 people in compa-

nies throughout Europe, and in the United States

and China. Shape is the customer magazine of

the Sapa Group and is published twice annually

in 14 languages. Shape is also available from

www.sapagroup.com.

Editor-in-Chief: Eva Ekselius

Editor: Anna-Lena Ahlberg Jansen

Graphic design: Karin Lwencrantz

Production: OTW Publishing

Prepress: DONE

Printing: Davidsons Tryckeri, Vxj

Cover photo: Stefan Ideberg

Changes of address: Customers should inform

their contact person at Sapa, employees their

salary department and others the Communicatio

Department on +46 (0) 8 459 59 00.

Shaping the future

1

108

Clever fly-bar guides carry stagesets at the Royal Swedish Opera.

220

Lighter and environmentally friendliercars are two challenges for the auto-motive industry.

FSW sped up manufacture ofhigh-speed ferry in Hawaii.

Ole Enger,

President and CEO

Sports inspired Volvo designerSimon Lamarre.


3/24# 1 2007 SHAPE

Spotlights thatcan stand the heat

BRIEF NOTICES

Wembley Arena in London and superstar Robbie

Williams have something in common: they use

lighting systems from the Danish company Martin

Professional, a global leader in computerised lighting.

Regardless of the lighting systems size and

application area, the bulbs in spotlights generate

a lot of heat and need cooling down. This is done

with aluminium cooler profiles.

If the spotlight is to be installed outdoors, it also

has to be corrosion-proofed.

Aluminium is an extremely effective heat conduc-

tor, and Sapa has a lot of know-how in integrating

functions in an aluminium coolers profile, says

Hans Christensen, sourcing manager at Martin

Professional.

Martin Professional and Sapa have jointly

designed cooler profiles for two spotlight models

for lighting buildings so far, and both companies are

keen to develop this collaboration.

Todays strong interest in interior design has

increased demand for designed sliding doors.

Prisma is a new line of sliding doors from Elfa

with profiles in natural anodised and veneered

aluminium.

These products are sold by professional

building material dealers. They consist of made-

to-measure floor-mounted sliding doors with

aluminium side profiles, floor tracks and ceiling

tracks. Sapa Profiler in Sweden was involved in

developing them, and supplies the highly value-

added profiles.

The profiles play a crucial role in the new

sliding doors design. Aluminium offers added

stability and a wider range of exciting design

options than steel and wood, explains Marcus

Grimer, in charge of sliding doors at Elfa.

Prismas profiles are made of brushed alu-

minium in silver, bronze, white and chilli. The

veneered profiles are available in birch and oak.

The sliding doors are also available with attrac-

tive veneers in various designs, foil surfaces, and

reflective and coloured glass.

The bottom wheels on Elfas sliding doors

have ball bearings for smooth, silent action.

The doors entire weight rests on the floor

track, making it easier for our customers to

install them in their homes, says Grimer.

Sliding doors withan exciting design

Air conditioning in large commercial and industrial

environments is a new business segment for Sapa

Heat Transfer. The client is Danish company Alu

Heat Exchanger.

Sapa Heat Transfer mainly works with the auto-

motive industry, but the new contract also opens

the doors to the stationary cooling unit market.

Three Sapa companies collaborated in

developing the product. Sapa Heat Transfer in

Finspng, Sweden, and Sapa Heat Transfer Tube

in Remscheid, Germany, developed the tubes and

tanks, while Sapa Technology supplied know-how

in refrigeration technology. Production will initially

be done in Europe, and will later also take place in

China.

Creating pleasant building environments is a new

challenge for us. We also see opportunities for creat-

ing added value by offering more ready-made com-

ponents for the systems, says Kennet Persson, busi-

ness developer at Sapa Heat Transfer in Finspng.

For decades, stationary air conditioning systems

have mainly been made with copper materials.

Aluminium-based materials significantly cut manu-

facturing costs. Demands for more energy-efficient

operation of air conditioning systems is another strong

reason for changing manufacturing techniques.

New business segmentfor Sapa Heat Transfer


4/24 SHAPE # 1 2007

Whatsmoreimportantis workingin a stimulatingenvironment whereeveryone pulls inthe same direction.


5/24# 1 2007 SHAPE 5

Ole Enger has beenSapas Chairmanof the Board since

. Hes been asenior executive inseveral major compa-nies including NorskHydro, Elkem and

Orkla. Through his work, he has gained yearsexperience of the American aluminium company

Alcoa, whose profile activities are now beingmerged with Sapas. Engers broad experience isalso the main reason why he became Sapas newPresident and on th February. Hes cur-rently dedicating of his time to the merger.

Merging two companies this big is a hugeundertaking, he says. Im in the unique position

of being very well-acquainted with Orkla, Alcoaand Sapa. I would never have become Sapas if we hadnt been about to embark on this jointventure, he says.

ENGER GREW UPon a farm in Hokksund outsideOslo, Norway. Even before taking his first job a summer job as a scrap dealer he was alreadyexperienced in business.

I was only ten years old when I started takingan interest in business, he says. Because I livedon a farm, I dealt in everything from animals tostrawberries and Christmas trees.

Enger ended up in the aluminium industry by

chance. After working as a business developer atNorsk Hydro, he joined Elkem in the early s.

It was a completely different world. I hardlyknew what aluminium was then. Ive been work-ing with aluminium ever since. After Orklaacquired Sapa, I specialised in profiles.

Although Enger already knows the industrywell, hes always thirsty for more knowledge. Hesays he needs to learn more about the technicalprocesses in the companys profile activities.

Im not an office person. Every day I long to

Ole Enger in brief

Age: 59.

Home: Apartment in Stockholm.

Family: Wife and three grown-up children.

Favourite reading: Anything about history.

We need more knowledge about our history.

Favourite films: Prefers theatre, opera and

concerts to the cinema.

Music: Classical music, preferably at con-

certs.

Favourite place in the world: China. The

Chinese are generally open to new ideas and

knowledge.

Car: Volvo XC90.

Favourite food: Chinese and Japanese food.

What you didnt know about Ole Enger:

As a teenager I performed as an actor at

weddings and other occasions. I performed in

Ibsens Peer Gynt.

visit our production locations, he says. I want tounderstand whats going on when I walk aroundSapas facilities, so I have to learn about the extru-

sion process. If you want to stimulate and inspireother people, you have to know whats happening.This is also essential for good communication

with the organisations employees.Its also about respecting the whole production

chain. All parts of production are equally impor-tant. Before creating a vision for Sapa, I need tofind out what we have to do to become globalleaders. Too many people create visions that arentbased on reality.

ALTHOUGH EN GER HAS only recently become ,hes already clear about Sapas direction.

Sapa Profiles is a global leader today, Heat

Transfer has a very strong position and BuildingSystem needs to get bigger. The aim is to createa company that is competitive throughout the

whole production chain. To succeed at this, weneed to introduce the Genesis business system.Then well become leaders in all three businessareas.

What will Sapa look like five years from now?Sapa will be considerably larger than today, withimproved productivity and stronger customerfocus. Our market shares and profits will haveincreased, paving the way for expansion in theeast. Building Systems and Heat Transfers posi-tions will have improved. If we dont achieve this

in five years, well have failed.Enger describes himself as deeply committed to

organisational development. He feels its vital forSapa to continue applying a decentralised organi-sational model after the merger with Alcoa.

In this transaction, weve made it clear rightfrom the start that we want a decentralised organi-sation. Sapas model allows the employees in theproduction chain far more influence than in tradi-tional organisations. This process must continueright out to the operators.

His first job was as a scrap dealer. Ole Enger still workswith metal today but now its aluminium. In February,he became Sapas new President and CEO.

When asked to summarise the most importantaspect of a job, Engers answer is human contact.

Whats more important is working in a stimu-

lating environment where everyone pulls in thesame direction. I aim to maintain contact witheveryone in the whole organisation. I find thatvery rewarding.

TEXT CARL HJELMPHOTO SUSANNE KRONHOLM

MeetOle Enger


6/24

Bed manufacturer Hstens collaborated with Sapa in developing their topmodel, in which steel and wood have been replaced with aluminium profiles.

Aluminium is lighweigh and has an elegan, simple look, says

Emma Sandsj, Hstens communications manager.

6 SHAPE # 1 2007

Aluminium dreams

Swedish bed manufacturer Hstens is afamily company founded in 8 andnow run by fifth generation bed special-

ists. Hstens has been a purveyor to the RoyalCourt of Sweden since 1952.

In 2005, Hstens decided to developCitation, the top model in the companys range

of adjustable beds. Aluminium was the materialthey chose.

We wanted to take the model to a new level.Our aim was to achieve greater functional-ity, a light base and an attractive design, saysSandsj.

Most of Hstens product development takesplace in-house. However, because the companyhad never worked with alu-minium before,

Hstens contacted Sapa in August 2005.Sapa helped with the product development

and we tested different solutions, says Sandsj.We soon found a base that was suitablefor Citation. Our collaboration with Sapasproduct developers was highly successful, andour combined know-how produced excellent

results.

THE PRODUCT DEVELOPME NT FOR CITATION ended inlate 2005. Sapa has manufactured aluminiumprofiles for ,8 beds to date. Productionincludes extrusion, processing and surfacetreatment.

Citations base was previously made from a

combination of steel and wood. Sandsj seesseveral advantages from using aluminiumprofiles.

The design aspect is important, she says.Aluminium is a popular material right now. has an elegant, simple look that appeals to oucustomers. Aluminium also makes the beds

lighter and easier to use.Another advantage is that the base consists

several components that are screwed instead owelded together.

The new model was launched in spring2006, and the new Citation is a hit withHstens customers.

Citation is definitely a popular bed. Weexpect sales to increase significantly in 2007,says Sandsj.

tExt Carl Hj


7/24# 1 2007 SHAPE 7

BRIEF NOTICES

The Estonian company Ldiamon manufactures state-

of-the-art equipment for dialysis monitoring. Even the

seemingly simple support tube in aluminium profile is

carefully designed down to

the last detail. Despite its

diameter of just four centime-

tres, it needs to contain seve-

ral cables for the devices

LCD screen and rubber

tubes for various medicines.

Whats more, its height

needs to be adjustable.

Theres a fairly small mar-

ket for this type of device,

so its not a huge seller. But

its an interesting example

of how these devices are

advanced all the way, says

Taavi Saksen, sales engineer

at Sapa Profiilid in Tallinn.

High technology

all the way

Tents are a necessity after natural disasters, or during military operations such as the conflicts in the

Middle East. J&S Franklin are the leading supplier of tentage to the British Armed Forces, so the company

needs a vast supply of aluminium tent poles.

The company bought tent poles worth over SEK 17 million in 2005 alone.

We have successfully completed a trial order of 5000 poles and have received orders for a further

100,000. We hope to sign a further three year contract during May 2007 says John Ward of Sapa

Profiles Limited in the UK.

Tent poles galore

The Dutch company Apollo manufactures verticaltransport systems a must for transporting anythingfrom tea bags to truck wheels inside factories. TheSpiral Conveyor enables customers to save space andimprove transport flows between storeys. This modelhas been further improved and is now made of alumini-um profiles.

Thanks to a successful collaboration with Sapa in theNetherlands, we can manufacture the Spiral Conveyordirectly to order, cutting production time by 25 percent.This model also runs more quietly now that its made ofaluminium, says Arnold Duim at Apollo.

Taking transportto new heights


8/24

Energy-intensive to make but easy to recycle.

Today,95% of all the aluminium

in a car is recycled.Aluminium is quite an impractical material in a throw-

away society, but perfect in an environmentally

conscious one, says Johan Lindstrm, CEOof the Swedish Aluminium Association.

Aluminiumlightens up energyconsumption

choice of mterils. Design engineers mkepersonl choices, sys Lindstrm.

Nevertheless, mny trditionl steel ndcst iron vehicle prts hve been replced withluminium over the yers, for instnce engineblocks, bumpers nd the unit behind the bumpertht bsorbs collision impct. Aluminium is lsoused in mny fittings, such s the trcks used forttching roof boxes.

Aluminium is now incresingly replcingsteel in body detils nd metl sheeting. Some crbrnds hve been using luminium for quite long time in specific production series, but now itsbeing used more nd more in stndrd crs, sysLindstrm.

He points out tht luminium in crs is nothingnew. Few people re wre tht Lnd Rover hshd n luminium body since the 1950s. Morerecently, Audi hs been forerunner by buildingthe entire chssis of the cr in luminium. The

Audi a8 ws lunched s erly s 1994. This wsfollowed up in 1999 with the Audi a2, nother

Approximtely 50 million pssenger crs remnufctured nnully worldwide, ndvehicle fleets hve become progressively

heav- ier in recent yers. This is becuse equip-

ment such s ir conditioning, irbgs nd othersfety fetures re now stndrd in mny vehicles.

These units weigh quite lot. Whts more,vehicle bodies hve generlly been reinforcedto meet incresingly strict industril stndrds,explins Lindstrm.

Comfort nd sfety re strong driving fctorsin vehicle development. Another key fctor isthe environment. There is politicl mbitionto reduce dependence on oil, nd the limitsfor crbon dioxide emissions re decresingin mny countries. This will nturlly ffectengine development, but there re more wys ofimproving crs fuel economy. After ll, smll,light cr consumes less fuel thn lrge, hevy one.

A mjor chllenge for todys utomotiveindustry is to reduce vehicle weight whileincresing sfety nd comfort, sys Lindstrm.

THE SOLUTION IS TO utilise new, lighter mterils.Plstic, luminium nd mgnesium reincresingly being used in vrious componentsto reduce vehicles weight while rising theirperformnce.

Theres still huge untpped potentil here.Theres lot of new technology to lern, ndmny outmoded ttitudes persist regrding

8 SHAPE # 1 2007

ENVIRONMENT

model mde lso entirely of luminium both tbody nd the lod-bering structure.

Competing mterils for vehicle constructioninclude crbon fibre-reinforced plstic, which islso very strong in reltion to its weight.

The problem is tht it cnt be recycled ndisnt bsed on renewble source. But buxite, thrw mteril tht luminium is mde from, is virtully infinite resource.

MAKING ALUMINIUMfrom buxite is energy-intensive. It tkes lot of electricity totrnsform luminium oxide into metllicluminium through electrolysis. However,most of the luminium used in crs is so-cllesecondry luminium mde from recycled csiron.

Its the sme qulity s primry luminiumnd this is one of the mterils big benefits. Icn be recycled repetedly without impiringits qulity. Whts more, the recyclingprocess requires very little energy just 5%


9/24# 1 2007 SHAPE 9

of the energy required to produce primaryaluminium, stresses Lindstrm.

Theres an enormous supply of raw materialfor recycling. All the aluminium products ineveryday use today have a total weight of about460 million tonnes. Meanwhile, approximately27 million tonnes of aluminium are producedeach year, and use of aluminium is increasingby 5 to 10% every year.

LINDSTRM SEES MANYfuture opportunities forusing aluminium to promote environmentalsustainability.

For a start, all products should be made lighter.Take fridges, for instance. Replacing the steel infridges with aluminium wouldnt make muchdifference to households. But it would play acrucial role in reducing carbon dioxide emissionsfrom worldwide transport. Reducing a products

weight means using other materials. This appliesto white goods, home electronics and otherconsumer goods.

The construction sector also has muchto gain from using aluminium. Here thebiggest benefit isnt weight savings butlower maintenance also an importantenvironmental factor.

Aluminium can replace steel and wood inframeworks and facades. Among other things,this saves the need for repainting. This iscommon in the United States. Skyscrapers andother large constructions are usually made ofglass and aluminium. Aluminium requires notreatment at all and lasts for hundreds of years.It doesnt even need washing, says Lindstrm.

As a piece of historic trivia, he mentionsthe Church of San Gioacchino in Rome, builtin the late 19th century. Its roof was made ofaluminium instead of copper as a status symbol;aluminium was extremely expensive back then.

Its still in great condition today and needsno renovation, he says.

tExtSuSannaLidStrm

illuStrAtionheLena Lunding


10/2410 SHAPE # 1 2007

Profile production is the basic activity in Trzciank

but the future lies in increased compone

manufacture with increasingly value-added produc


11/24# 1 2007 SHAPE 11

INSIGHT: POLAND

apa in Pland ha a trng pi-

tin n th dmti martand i a ladr in many ara, f

whih th ntrtin indtryi by far th largt. Bt mp-titin ha inrad. Evryn

want a har in Plandntrtin bm and th

nw infratrtr invtmnt initiatd inPland ain t th eu.

Pland harp nmi grwth ha ldt a bm in ntrtin. Nw airprt,ffi mplx and htl ar grwing pvrywhr. That whr w m in whav th nw-hw and rr and ar wll-nwn a a rliabl, lid bin partnr, ayceo Ptr Arndt.

Fiv yar ag, h prditd that th mpanywld dbl in iz by tday, and thi viinha bn ahivd. Sal hav rin frm sek325 millin in 2002 t vr sek 750 millin in2006. Ptr viin al inldd ahiving anxprt rat f half th mpany Plih prd-tin.

Wr nt qit thr yt, bt th xprt rati alrady mr than % bad n vlm.D t r inrad prprtin f mahindprfil with highr addd val, thi figr i

lightly highr whn

allatd n thbai f nt al.

Grmany i thmpany biggtxprt mart, anddmand fr mp-nnt ha inradharply thr inrnt yar. Exprthav al inrad tth Czh Rpbliand Slvnia, andinitiativ ar albing tan frthrat.

Wv tartdtablihing ntatin Urain andBlar. W xptbin t ta ffthr in th lngr trm, h ay.

IT ALL STARTED IN nrth-at Pland, inTrziana, a twn with a pplatin f20,000. Sapa Pland tablihd it firt prhr in 1993. Sin thn Sapa, with jt vr700 mply, ha bm Trziana larg-

t mplyr. Th mpany al managr,Marzna Winiwa, wa thr at th tart.

Whn Sapa wa tablihd in Pland 14yar ag, thr wa nthing hr. W didntvn hav any pr fr r prdtin whnmy al rp tarting ntating tmr.

W had t patintly xplain what alminim

Sapa Alumums Pols CEO keeps s pomses. Te

compays busess as ouble fve yeas. Pete Aet

opes tat ew investment in tailored solutions wll elp

make te ext fve yeas equally successful.

FOrging AhEAd in

Poland

P h O T O : P i O T r

M A l E C k i / S P E C T r u M

P i C

T u r E S

The Polish building boom is creating many new offices and hotels.


12/2410 SHAPE # 1 2007

er Arendt

Piotr Wieliski

We aim to supply as manycomplete products as possible, andwere getting more and more of thistype of order

profiles are and what they can be used for.Things are different today. Now our custom-ers know what they want and what demandsthey can make. The markets knowledge hasincreased just like ours has, says Winiewska.

The press that was installed in 1993 is still inuse, but continuous investments have been madesince then. Last years installation of a third pressfor wider profiles and harder alloys has doubled thecompanys capacity in Trzcianka.

Almost 90 percent of our produced goodsare customised, and many of our 6,500 speciallymanufactured tools are made in Trzcianka, says

production manager Piotr Wieliski during a tourof the factory.

ROUGHLY 40 PERCENTof the manufactured productsare anodised. There are already two anodisingplants in Trzcianka: a new one installed in 2006and an older one in use since 1994. During theautumn, the older plant will be replaced with anew, larger, more efficient plant next to the recentlyopened modern treatment plant. Environmentalissues are of top concern, and all aspects of the newplant will comply with strict standards.

Various types of fabrication, including weldingand assembly, take place in rooms next to the press-es and in a building on the other side of Trzcianka.Wheelchair components for Etac in Germany,says Piotr Wieliski pointing to freshly weldedaluminium frames. A little further away are roofrack components for the Swedish company Thule,shower panels for Rocca in Spain and parts of solarpanels, which could become a new, growing mar-ket. However, Wieliski is most enthusiastic abouta stack of boxes ready-packed with goods. Theycontain complete kits for the telecom companyEricssons products.

This is where the future lies. We aim to supplyas many complete products as possible, and were

getting more and more of this type of order, sayWieliski.

He calls it a one-stop shop concept. Sapa pro-duces aluminium parts and supplements them

with purchased components, all adapted to thecustomers production needs. In some cases, thecompany supplies finished products packed andready according to specification.

WHILE PROFILE PRODUCTIONand anodisation willremain the basis of the companys production, threal growth potential lies in components a viewshared by Peter Arendt.

The next step is to develop component prodution in d, where Sapa currently has a poweredcoating plant. A new company, Sapa Komponen

will primarily produce components for the auto-motive industry. The decision to establish prodution in d rather than Trzcianka is due partly tds accessible location in central Poland, andpartly to the university and colleges in and around, which will provide an excellent recruitmenbase.

Were already Polands biggest componentmanufacturer. Now we want to supply as manyvalue-added and ready-packed products as possiband offer customers everything from productionsolutions and product design to final assembly andistribution. In Poland, were just starting out anhave a long way to go. But we see this as an excitichallenge, says Arendt.

TExT: SuSanna Lindg

PHoToS: Jan Brykczy


13/24# 1 2007 SHAPE 11

When the Slovenian household appliance company Gorenje had finished

designing the aluminium panels for its new exclusive Pininfarina line of

kitchen products, it started looking for a manufacturer to produce them.

However, few could meet the challenge. The first attempts were made

by manufacturers in Italy, the native country of Italian designer Paolo

Pininfarina. But in the end, it was Sapa in Sweden that succeeded in

producing the goods.

None of the first manufacturers we asked could meet our requirements

for quality and durability. The design is unusual because the door panels and

handles are made in a single piece, explains Irena Penik, executive assist-

ant at Gorenjes purchasing and logistics department in Velenje, Slovenia.

Gorenjes collaboration with Sapa started in the office but continued in

the factory. Representatives from Gorenje, including Penik, attended the

first trial pressings in Finspng, Sweden.

The panel has a very unusual shape. The biggest challenge was the

c-shaped handle, says Penik.

Sapa also proposed some changes that resulted in a thinner, lighter

panel, which in turn reduced the load on the doors hinges.

Part of production is still located in Sweden, but thanks to our new,

larger press in Trzcianka, well soon be able to move all production there,

says Franc Abram, export manager at Sapa in Poland, who initiated the

collaboration with Gorenje.

Sapa delivers Italian designs

INSIGHT: POLAND


14/24

imon Lamarre, studio chiefdesigner at Volvo Cars inGteborg, says it straight awayto avoid misunderstandings:

designing and developing anew car model is no one-man

job.Its definitely a team effort.

Anyone who claims otherwise is lying.It took several years to design the , and

over people were sometimes involved in theprocess. And thats not counting the productionstaff, marketing staff etc.

Of course, only a few key individuals had thekey roles.

Naturally, as a designer I had to take a lead-ing role and make sure the ideas were put intopractice, says Lamarre.

Lamarre explains that he has a creative rolethroughout the whole process, although mainlyin the beginning until the model andtheme have been decided on.This is followed by anintensive phase wherethe designer col-laborates with theengineers to choose allthe system solutions andensure that they work.

On the road to achieving a finished car there

are several stops when both the cars design andtechnical function are meticulously analysed.The longer the process takes, the less creativeand artistic freedom there is. The process passes

from a preliminary design with ample freedom,via a stage where the parts and features can bechanged or moved a maximum of 5 mm, to thenext stage where they can only be moved halfa millimetre. Finally, all parts of the technicaldesign are completely locked. In car speak, thisis known as a frozen product.

Deviations are always a point of discus-sion and a matter of give and take between thedesigner and design engineers. And things arenever the same for two models. Its an organicprocess.

DURIN G THE PROJECT,Lamarres job becomes pro-gressively less artistic and increasingly focusedon solving technical problems. But good

design is always part of theprocess.

I sometimes jok-ingly say that myjob consists of percent design and

percent nagging.My job is really about

selling the design conceptto everyone else involved, he says.

Simon Lamarre in brief

Age: 38.

Training: Product design at UQAM,Universit de Qubec Montral.

Background: Moved to Sweden in 1990 and

joined Saab as a clay modeller in 1992. Three

years later, he joined Volvo and got them

to switch from clay modelling to computer

modelling. Worked on the interior design of

the Volvo XC90. Has worked on the C30s

interior design since 2002.

Cars: Volvo V70 (hes a father of three), but

the C30 is on his wish list.

Favourite car: Austin Healey and Volvo C30.

He describes himself as a cross between an artist and

an engineer and he loves both of these roles. Canadian

Simon Lamarre is the designer behind the new Volvo

C30. This car is expected to be a big seller among urban

singles and couples with an active outdoor life.

S

SIMON LAMARRE

PROFILE

14 SHAPE # 1 2007


15/24

I sometimes jokingly say that my job

consists of 10 percent design and

90 percent nagging, says studio chief

designer Simon Lamarre.


16/2416 SHAPE # 1 2007

PROFILE

through brushing, ething, laquering or printing says Lamarre, who feels that aluminiumould be used muh more in ars than it is tod

As a designer, he likes to use aluminium for aestheti value, but of ourse the environmentaspet is important too. Aluminium is usedin the c30s wheels, bonnet and other partsto redue the ars weight and thus ut fuelonsumption.

Environmental regulations will mean a lot hanges for ar manufaturers, and aluminiummeets many of the new riteria. But the designengineers have more influene than we do overthis aspet, for instane when they hoose thematerial for a seat frame.

Another environmentAl benefitof aluminium isreylability. The obvious drawbak is its pri

Some manufaturers make whole ars inaluminium, but thats very expensive. You neto onstantly ask yourself what ustomers areprepared to pay. Its a balaning at.

When asked what he thinks ars will be like

Small part with a vital function

themselves these three questions. The answersthat emerged had a lot to do with boards andboard sports. Many of the target onsumers areskateboarders, snowboarders and wakeboarders,and dress in the style assoiated with thesesports.

The result was a sporty ar that was small byVolvo standards, primarily designed to holdone or two people and their luggage or leisureequipment.

from A teChniCAl AnD DeSiGn perspetive, both newand old solutions were used to attrat the newtarget group. The team wanted the ar to look ool

and showy, but to still have details that learly showits a Volvo. One of its ool, sporty elements is thebrushed aluminium entre onsole. The onsolessurfae an be varied. For instane, it an bedeorated with a surf motif that looks like a wavehas washed over it.

Aluminiums appearane an be varied a lot

All this hard work is rewarded when the fin-ished model is finally ready. Then the projetteam gets the new lease of energy required totakle the next projet.

Its an enormous kik to see a finishedprodut roll out for the first time. Its almostunreal, says Lamarre with a huge grin.

But getting bak to the drawing board andthe omputer where do the inspiration andideas ome from during the reative proess?

People often ask me that, and I still dontknow what to answer. Its about reating afeeling, and that an ome from anywhere.It an be evoked by a gadget in a shop. Or by

going away from your everyday environmentand doing something different. Or by visitinga fair.

Many of the ideas for the c30 ame fromsport and fashion. What do the target group doin their free time? How do they dress? What dothey expet from a ar? The projet team asked

1 2

6

Sapa manufactures a support component for the

Volvo C30s B-pillar (the pillar behind the door). This

aluminium profile is a safety-related part that helps

the B-pillar deform as intended by the cars desig-

ners in the event of collision.

The profiles unique properties have been

utilised by adding an additional function in the

cross-section: a hook that partially supports the

seats. This function wouldnt have been possible

if the part had been made of a different material.


17/24# 1 2007 SHAPE 17

1, 2Thealuminiumcentreconsolemakesitpossibletovaryandpersonalisethesurface,forinstance

throughbrushing,lacqueringoretching.

3. AccordingtoLamarre,therearlightsaretheVolvoC30srealpicedersistance.Alltheexpressive

shapescometogetherinthebroadshoulderlinetypicalofamodernVolvo.Whatlookslikechrome

insidetherearlightsisactuallyanaluminisedplasticsurface.

4. Aluminiumdetailsinandaroundthegearlevergivethecarasportylook.

5. Thesportylookisenhancedbybrushedaluminiumdoorhandlesinsidethecar.

6. Thedesignerschosealuminiumforthesteeringwheeltosaveweight.

7. Volvoandmanyothercarmanufacturershavelongusedaluminiuminwheelstoreducethecarstotal

weight.

8. TheC30sspoilerisahighlyfunctionaldetailthatimprovesaerodynamicsandstabilityathighspeed.

in the ftre, Lmrre predit mixtre of oldnd new, jt like with the c30.

In ome wy they wont differ ll tht mhfrom tody r. Bi fntion like for wheelnd teering wheel will remin the me, btnew mteril nd tehniqe will ffet bothperformne nd environmentl impt, he y.He lo ee r beoming more dptble toowner reqirement, whih my hnge dring r lifepn. Byer will lo be ble to e theirr to expre their peronlity nd imge throghtheir hoie of dpttion nd dd-on.

Bt Volvo Cr i till onentrting on thec30. The ompny im to ell 65,000 r yer.The c30 h lredy been lnhed throghotErope, with Jpn nd the usa oon to follow.Lmrre y tht working on the c30 h tghthim good del bot both internl nd externlmrketing. And he optimiti:

Im firly onfident tht I old ell c30 tojt bot everyone on the plnet, he y.

TEXT THOMAS STBERG

PHOTOS STEFAN IDEBERG

43 5

7 8


18/2418 SHAPE # 1 2007

ON THE ROAD

Volvo Cars and Sapa spent over three years brainstorming ideasand technical solutions. The result: an aluminium cargo rail withunique functions.

The eelopmet work has bee gog ose 2004. The ew argo ral (kowto sers smply as the ral) s part

of Volos efforts to make ts ars safer. Butts also a result of ew regulatos uer din(Deutshe Iustreorm), whh requreall ar maufaturers to equp ther ehles

wth fasteg pots apable of seurg ammum amout of argo.

The soluto eelope by Volo, wth Sapaas a ate eelopmet parter, replaes thesteel rgs o preous moels of the v70 a

xc70. What makes the soluto uque s thatthe four hooks the floor rals a be moeaywhere alog the rals, a they a befole flush wth the floor whe ot use toao amagg argo as t s pushe alogthe floor.

It was a real hallege to esg hooks thatwere free eough to moe, but t moe

whe they weret suppose to. They alsoha to be loke the rase posto, saysHka Muhr, key aout maager at Sapa

Automote. The alumum ral also elmatesthe ee for brakets, se the etre floor ofthe argo spae rests o a flage protrugfrom the ral. Whats more, the se paels areserte to aother flage o the argo ral,makg use of the alumum profles apatyfor tegratg arous futos the proflesross-seto.

THE SYSTEM ALSO INCLUDES fasteg hooks thepaels uer the se wows.

Ths allows the opto of seurg theloa three-mesoally, somethg that oother ar maufaturer a offer, says CarStemark, projet maager at Volo Cars.

The ew moels of the v70 a xc70 wll htthe market ths autum, a Sapa wll supply

200,000 argo rals aually, osstg ofetrue profles a moute aessores.

Volo has lassfe the argo seurgsystem as a uque sales fator. Ths meas ththe system offers ustomers ae alue athus helps sell the ar, says Stemark.

SHE REPORTS THATthe ollaborato betweethe ompaes worke well, a that theyfou ways of workg both faster a moreeffetly urg the ourse of the projet.

Volo s harge of the esg, but wesole both bg a small problems together,she says. Sapa otrbute aluable eperta kow-how.

Volo wll also be offerg aessores suh mesh ers a slg argo floors for theew argo seurg system.

TEXT THOMA S STB E

Good news

for carGo


19/24

The fourth Aluminium Design prize was awarded

in October 2006. The prize is organised by

the Swedish trade organisation The Swedish

Aluminium Association. Of the 52 entries, the one

that appealed most to the competition panel wasBladvila, a park bench. The bench is designed by

Joanna Eriksson and made from a single aluminium

sheet. The first prototype is currently in production.

(This was the first prize in the competition.) Eriksson

is a freelance designer who creates glass products

as well as furniture for public areas.

I wanted to design a sculptural bench for public

parks that also serves a decorative purpose. Using

aluminium made the bench much lighter, and

just as importantly aluminium doesnt rust, she

explains.

What the panel said:

Poetry in aluminium thats a fitting description

for Bladvila when it casts its leafy shadows. This

bench also provides a place to sit and rest for a

while. Bladvila has a traditional sofa shape that

harmonises beautifully with nature. Its design

language is bold and unconventional, but also

friendly and inviting.

Design prizefor park bench

Flat monitors have conquered homes. Sapa Profiles

in Sweden has designed an adjustable arm in

anodised aluminium for mounting flat TV screens

and monitors to the wall, table or ceiling.

The product is part of the Linj concept that is

made by Gtessons. Linj is available in endless

possible combinations for both offices and homes.

Gtessons has sales throughout Scandinavia and

in some parts of Europe.

Light stand

for light monitors

Lars-Gran Borg, at TekniskService, Sapa Profiler offers tipson dimensions and tolerancesfor better visual design.

When profiles meet at right angles, or when

end covers need to be joined, its important to

design the joints in a way that looks attractive.

A simple example is when two rectangular

tubes meet at right angles. Because the pro-

files always have a corner radius, a groove is

formed and any misalignment will be clearly

visible.

The solution is to extend the corner

(see fig. 1). A short straight section between

the corner and the connecting profile hides any

misalignment. Often there is no need for spe-

cial tolerances, which has economic benefits.

Because of tolerances on end covers and,

primarily, on the profile, the outer contours

seldom coincide exactly. This problem isalso solved by making the end cover slightly

larger (see fig. 2).

Its hard to put an end panel on large

U-shaped profiles, since the gap size has

a relatively high tolerance. One solution is

to divide the U-shaped profile into several

smaller sections with built-in joints so that

the holes in the end panel guide and lock the

profiles to the exact dimension (see fig. 3).

The profileschool

Fig.2

Fig.3

Fig.1

BRIEF NOTICES

# 1 2007 SHAPE 19


20/24

VINJETT

20 SHAPE # 1 2007

PROFILEN

Felbild

STAIRWAY TO HEAVENWibes has been making ladders for over 75 years,

and is one of Europes leading manufacturers.

The companys factory in Nssj, Sweden pro-

duces 2,000 tonnes of aluminium ladders every

year. All the ladders are carefully tested to meet the

European EN 131 standard as well as the stricter

Swedish SS 2091 standard. All Wibes ladders

have a label specifying the ladders permitted

load, length and weight.

The tests are necessary when the

Swedish Labour Inspectorate inspected

roughly 2,000 workplaces, one in four

ladders failed to pass muster and had

to be replaced.

More and more pool owners are discovering the

benefits of a pool cover: no rubbish and debris in

the pool, lower heating costs and less need for

chemicals in the water.

Perhaps the biggest benefit of all is the safety

aspect. In many countries, pool owners are required

by law to comply with safety regulations. Putting

a fence round the pool is one solution, but the

Swedish company Pool-Guard has designed a

much better solution that is also safer for children:

a canopy with aluminium edge profiles that can be

rolled up.

Thanks to the anodised profiles, Pool-Guard has

a useful life of at least 20 years. That gives you time

for plenty of cool dips!

STAY COOL IN THE POOL

Summer safetyRainy and cold thats what a typical Scandinaviansummer is like. Thats why the type of glazed

patio extensions manufactured by Novoroom are

becoming increasingly popular. To withstand wear

from weather and use, all the patio frames are made

of anodised aluminium profiles.

With awnings on your house, you can decide

when to shut out the sunshine. With sales in

over 100 countries, Turnils is the global leader

in window covering systems. To withstand the

elements anywhere on the globe, parts such as

drop arms, roof rails and guide rails are made

of aluminium.

Welcomeshade

20 SHAPE # 1 2007

IN ALUMINIUM

SUMMERGOODS

SUMMER & SUNSHINE


21/24# 1 2007 SHAPE 21

At w fonded in Atri in 1988

with the viion of biding top-qityommeri vee for the gob

mrket. After five yer, the ompny w eding mnftrer of 40-metre pengertmrn. Tody, At i the word rgetmnftrer of high-peed ferrie, nd hdded miitry vee to it prodt rnge.In 2000, At opened new hipyrd inthe Amerin town of Mobie, Abm nd

won the order for the Hwii Sperferry thebigget high-peed ferry ever bit in the usa.

The ompny w o ontrted to bid theLittor Combt Ship (lcs) for the us Nvyin obortion with Gener Dynmi.

Weight i key ftor when biding high-peed vee, o minim i firy ntrhoie of mteri. Bt finding the right typeof minim in the usa for hip of thiize proved bigger henge thn Athd ntiipted. Chief rhitet Frnk Rynexpin:

No one ee in the us hd ever bid thitype of vee before, nd no other ompny

hd ever ed extrded minim to thiextent. The minim deivered to wdeformed nd beneth ritiim, whihed big probem.

It w t thi tge tht e mnger TogEgrimezer t Sp M Trnporttion in theUK ontted At.

Sp hd herd tht we mde rge -minim hip in the us nd offered to ppy with extrded minim profie, yChri Moye, hed of minim omponentt At. Up ti then, wed ony foed on

The Hawaii Superferry, built by Austal,

is a 107 metre long catamaran that

holds roughly 860 passengers and 280 cars. The

high-speed ferry travels around Hawaii.

When Austal opened a new shipyard in Mobile, Alabama in the

United States, they already had long experience of building

aluminium commercial and military vessels. The big challenge was

finding aluminium profiles that made the grade.

Superferry challengefor shipbuilder


22/24

Mass Transportation in brief

AgatewaytotheSapaGroupsglobal

resourcesforcustomersintherail

andshippingindustries.SapaMass

Transportationappliestheone-stopshop

concept,whereaspecialistteamtakescareofthewholeprocessfromdesignto

productionofextrudedaluminiumprofiles

andFSWpanels.

Offersdeliveryofprofilesfromthepress

facilitythatismostconvenientforthecus-

tomer.AustalUSAgetaluminiumprofiles

fromSapaProfilesIncinPortland,USA,

FSWpanelsfromSwedenandlargealu-

miniumprofilesfromSapaRCProfiles

inBelgium.

TheLittoralCombatShipisdesignedasatrimarantowithstandroughweather.

22 SHAPE # 1 2007

the t mte, hh h to nn the us. We gve Sp hne, n they kept

the pome.

SAPAS FIRST DELIVERY OF mnm poe o the H Speey. The next pojet, thet lcs hp, h onge e tme, o Ath hne to ty Sp pot potoon gete et. The ompny hoe to nto-e ton t eng (FSW), tehnqetht gve At mny benet.

Wokng th nv MIG-ee -mnm poe eqe vey hgh expete,expn Moye. In 2004 e h 120 empoy-ee t o Mobe pnt, n ke oke

ee n extemey hot ppy. Ung fsw gve hge potent o vng on mnpoe.

Sp 2.2 mete e fsw pne oe to t o poton eoe oneby.

A hp be, e mee o eeny bythe nmbe o okng ho pe tonne t tketo b vee.

Bee hge vng n okng ho,At o vng on onmbe mteh g n eng e. By ng fsw, theompny h o ove the pobem o nngke bo.

At enty bng the eonH Speey, n pn to tt ok on

t eon ics hp n m-2007. Th mentht mnpoe vng be even moe

mpotnt to the ompny te e.Athogh fsw h pove pt o-

ton to At hp poton pobem,Sp M Tnpotton pye n eqympotnt oe n the ok. Tog Egmezeexpn:

O phoophy to eveop eton-hp th eh nv tome by ne-tnng the nee n nng ve-eoton. We m to be gtey to the SpGop gob eoe.

THE OFFER TO AUSTAL ente ppyng -mnm poe n fsw pne om Eopen mnm poe om Sp Poe In.n Potn, usa.

Toy, Sp o ppe pojet mnge-ment, r&d n ogt eoe. Aongto Egmeze, the oboton ey took o

hen gop o empoyee om At n theusa n At vte Seen to tke o-e ook t ht Sp h to oe. Both FnkRyn n Ch Moye gee th th, eengto the oboton mh moe thn b-ne e.

We y get qk epone om Spempoyee. Sp tehn expete men tht

e n get oton pte to o penee. They hvent jt hepe to ve on

mnpoe eve o ve tme n moneyon eveopment, y Moye.

TEXT LINDA TROTM

PHOTO AUSTAL

We can getsolutions adaptedto our specificneeds.


23/24# 1 2007 SHAPE23#1 2007 SHAPE 23

BRIEF NOTICES

New model

for screw portsScrew ports are commonly used for joining aluminium

profiles. Now a new template for screw ports means

that Sapas customers can easily test which type

of screw and fixing method suits their individual

product the best.

The template gives you a feel for which

screw to use when you develop a product. Its

completely different to just studying a draw-

ing and reading a table, says Anders Helander at

Teknisk Service, Sapa in Sweden.

The new template allows screws to be inserted in

both longitudinal and transverse directions. It can beused for everything from fastening end coverings on

rectangular profiles to screwing light fittings into place.

Solar energy is both renewable and environmentally friendly andmany experts are convinced its the energy source of the future.

The problem is that enormous solar panels are needed to provideuseful amounts of energy. Conergy, a German solar cell panelmanufacturer, has taken stock of this.

Conergy contacted Sapa when the company planned to design anew support structure for its solar cell panels. The supports rotateon two axes so they can follow the suns movement throughout theday. As a result, they produce 35% more electricity than fixed solarpanels.

Our collaboration started in July. I think Id misunderstood howbig these solar cell panelswere it turned out theywere 16 by 6 metres, laughs

Joo Almeida, sales directorat Sapa in Portugal.Sapa was able to supply

Conergy with ready-to-usesupports just one month afterthe collaboration started.

We hope that collaborat-ing with a market leader likeConergy will raise our profilein the industry in general,says Almeida.

Supporting solar power

An objects surface structure plays an impor-

tant role in its appearance. This naturally also

applies to aluminium profiles. Mechanical

surface treatment such as grinding, brushing

or polishing creates a structure that makes the

surface appear more dynamic and interesting.

The various types of surface treatment avail-able give designers plenty of scope for variety

without affecting the profiles technical func-

tion. A transparent surface layer means that

anodising can be combined with various types

of mechanical surface treatment:

Band grinding creates fine lines on the

surface in the grinding direction. The

coarseness of these lines depends on the

chosen grain size. Grinding with brushes

results in a silky, matte surface.

Polishing creates a smooth, shiny surface.

High-shine polishing produces a glossy

surface.

Tumbling is used for small objects. High-shine tumbling results in a smooth, shiny

surface and deburring removes burrs and

smoothes sharp corners.

Mechanical surface treatment takes place

before plain or coloured anodising. Anodising

can be done in a wide variety of colours. Depth

and shine make the profiles surface look more

appealing and emphasise its structure and

shape while maintaining the metallic feel. The

anodised layer is also extremely hardwearing.

Anodisation is primarily used for products and

parts where the surface finish is an important

factor, for instance interior details and furniture.

Surface treatment

in brief

The characteristics of aluminium profiles

are largely determined by their surface;

the type of coating, structure and shine

create different effects. A wide variety

of available surface treatment methods

give us plenty of options.

Loudspeaker housings.Imagine a square measuring 500 by 500

kilometres covered with solar panels in the

Sahara, the worlds largest desert. An area

of solar panels measuring 250,000 square

kilometres (less than 3% of the Saharas total

area) would produce energy equivalent to the

entire worlds energy consumption from

electricity, oil and nuclear power. Its a dizzying

thought. A solar power plant this large will

probably never exist, but it says a lot about

the power of sunlight.

Mighty solar power


24/24

Gold, crimson velvet and crystal

chandeliers greet visitors to

the Royal Swedish Opera

House in Stockholm. Things

look different backstage and

aluminium rails suspended25 metres in the air ensure

that the performance runs

smoothly.

Mechanical lifting devices and computertechnology reign supreme behind, aboveand below the stage at the Royal Opera

House. Suspended high up underneath the ceilingare some seventy fly-bars, which are hoisted up anddown. Fly-bars are the theatre term for the railsthat backdrops, spotlights and other set equipmentare fastened to.

The Royal Swedish Opera House is muchmore high-tech than many people realise. It hascutting edge stage technology, and has had sinceit was first established, says Jan Holmgren, stagemechanic at the Royal Swedish Opera.

It used to be necessary to suspend a wood andmetal guide device beneath the steel piping fly-bar,but this system was slow and had limited weight-bearing capacity.

TOGETHER WITHa colleague, Holmgren started look-ing at a combined fly bar and guide made from

used in Scandinavian opera houseshad practical shortcomings, anddecided to design their ownfly-bar guide. A wooden proto-type was produced at their owncarpentry workshop, and Sapa

was engaged to take part in thedevelopment work. Some twenty metre long fly-bar guides are inuse today, and the aim is for or fly-bars to be made of alumin-ium within the next few years. The Royal OperaHouses own fly-bar guide has attracted interest inthe industry, and may be adopted in other operahouses in the future.

The biggest advantage of our fly-bar guide isthat several functions are integrated into the pro-file, which was impossible with a steel fly-bar. Italso weighs less, so can carry significantly heavierloads says Holmgren

AND FINALLY

High-flying technology at the opera

Cross-sectionof the fly-bar

guide.

Sapa Group - Shape Magazine 2007 # 1 - Aluminium / aluminum

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