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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
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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.
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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
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Whatsmoreimportantis workingin a stimulatingenvironment whereeveryone pulls inthe same direction.
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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
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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
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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
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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%
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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
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Profile production is the basic activity in Trzciank
but the future lies in increased compone
manufacture with increasingly value-added produc
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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.
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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
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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
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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
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I sometimes jokingly say that my job
consists of 10 percent design and
90 percent nagging, says studio chief
designer Simon Lamarre.
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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.
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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
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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
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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
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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
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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
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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.
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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
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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.