Areal shots around the SGL ACF plant. SGL ACF logo next the driveway and on the office building. Diverse shots.

Creel Area. Riase precursor. Diverse shots. Precursor formed into a web.

Precursor oxidation level: white, gold, copper, brown, black. Diverse shots. Winding. Winding carbon fibers. Supervisory staff walks along oxidation ovens.

Low temperature furnace.

Areal shots Columbia River and Wanapum Dam. Diverse shots. Columbia River. Wanapum Dam. Columbia River. Dam with opened locks. Diverse shots. Priest Rapids Dam. Columbia River.

Creel Area. Steve Swanson: This is the creel area. This is the fist step in the carbon fiber process. In this area we take the polyacrylonitral and form it into a web to go into the next step of the process. Oxidation Ovens. Steve Swanson: The next step in the process is oxidation. The oxidation process stabilizes and oxidizes the material in preparation for carbonisation. Low Temperature Furnace. Steve Swanson: The next step in the process is carbonization. We have the low temp and the high temperature furnaces. This process provides the strength to the material. The Moses Lake facility converts polyacrylonitral to carbon fiber. The first step in den process is the creel area. In an other area we take the polyacrylonitral and form it into a web and prepare it for the next step which is the oxidation. In oxidation we oxidise the material and stabilise the material and prepare it for carbonisation. After oxidation the material goes into carbonisation stage where the material is carbonized and the filaments become a very strong bundle of material. The next step is the surface treatment. After carbonisation the material has no functionality. It is sterile at this point. So in this process we edge the outer skin of the material to allow it to a bond with resist system in later applications. After this we size the material, so we put a small amount of sizing on the material and this is really for usability and handlability for our customer. And after this we wind this material onto barrens and ship to our costumer in Wackersdorf. The Moses Lake facility utilises a high level of energy, much more than the other plants in the supply chain. Because of this we have to make absolute sure, that we are using renewable low cost energy for the program. Moses Lake was chosen for the side for our new facility mainly because of the low cost renewable energy provided by the dams on the Columbia basin river. Oxidation Ovens. Steve Swanson: This is the oxidation. This process oxidises and stabilizes the material in preparation for carbonisation. As the material is heated the material changes colour as the oxidation level increases. Oxidation Ovens. Steve Swanson: This is the second stage of oxidation were you can see the colour changes as the oxidation level increases. Oxidation Ovens. Steve Swanson: This is fully oxidised black carbon fiber. This material now is prepared to go to the carbonisation of the process. Winding. Steve Swanson: This is the final process in carbon fiber production: winding. And this is the final product we send to Germany.

Various exterior shots SGL Automotive Carbon Fibers – Plant Wackersdorf. Biaxial Machine. Unwinding spools, spreading of carbon fibers, warp knitting, tempering / binder application, winding the fabric. Unwinding between 90 to 560 spools depending on fabric width and area weight, redirection over several bars increase the tow width, warp knitting the carbon fiber glass layer with a defined pattern, shrinking of warp by heat input. Dispersion of binder powder. Heating up the binder powder, so that it softens, sticks to the fabric and partly soaks into it, winding the fabric onto cardboard cores. Cut after reaching the required length per piece.

Stacks (textile mats) are moved into preforming facility Process from front, side close-up. Stacks arrive at facility, are transported up for performing. A mat is taken and inserted. Geometry of component is created. Preform parts cut by robot. Preforming tool front side, total and close-up. Finished preformed parts on production line.

Preformed part is inserted in side frame. Grab arm is lowered to preformed parts packing table. Camera track: side frame from pre-packaging table to bottom tool. Press lowered onto component, mix head close-up for resin injection. Grab arm removes finished side frame from tool.

Side frame transported into facility. Various shots of robot cutting. Finished and cut side frame leaves facility.

Cells are provided in cartons. Cells are placed for testing and cleaning. Surface cleaning before bonding: plasma cleaning. Bonding agent applied to cells, diverse shots. Employee prepares aluminium pressure plates and isolation jackets. Joining and bonding the separate components into a module (12 cells in a module), diverse shots. Robot places module ready for use. Cell contacting system is placed by onto the module by employee. Laser welding. Completion of module manufacturing.

Aluminium container is placed in readiness and the cooling system is inserted. The individual components are assembled (high voltage connector, valve, electronics and cooling system). Modules (8 pieces) are automatically placed in the battery and bolted. Cable harness is connected by employee and the lid is attached. Lid is automatically bolted. Test bench.

Robot takes front axle module from turntable. Front and rear axle modules are positioned. Robot grabs side members and joins them to front and rear axle module. Welding of drive module. Bolting (connecting points). Measuring station. Depositing: Test bench. Drive module with high voltage battery and tires, various shots.

Wheel set assembly: press-fitting the bearings and joining the shafts. Teeth combing. Wheel set assembly. Wheel set is joined in the housing. Sealant applied by robot. Lid is pre-bolted. Lid is automatically bolted. X and O seal ring assembly and placing of the seal caps. Label is attached to E-transmission.

Areal shots Columbia River and Wanapum Dam. Diverse shots. Columbia River. Wanapum Coiling and necking machine: Copper wires are wound in coils. Presses: Forming the stator / expander: Coil is forced apart. Taping machine: The coils are fixed in place. Electricity/heat UV impregnation: Resin immersion. Rotor production: 6 sheet metal sections, 12 small and 12 large magnets are used respectively. Support discs are joined. Final assembly: Motor is mounted on workpiece carrier. Performance electronics are bolted to motor. Engraver: Motor number is engraved.

Thermoforming: Film is pulled in, stretched, heated and punched out. Backfoaming Foam is applied by robot. Carrier and plastic skin are bonded; softer surface. Milling station: Robot mills carrier into shape. Adhesive is applied to leather and carrier part. Press lamination: Adhesive is heated and then the leather is pressed onto the carrier. Infrared welding. Assembly: Cockpit is assembled, attachment parts are bolted on and the cockpit checked.

Main line chassis frame: Joining of side frame (right, left) to floor assembly. Cleaning and bonding. Side frame. Cleaning. Individual components are assembled. Test bench.

Injection moulding (plastic granulate is melted). The mass is injected and moulded. Frame and outer skin are bonded. Flame treatment. Injection moulding. Parts are placed on skits. Preparing for the paintshop. CO2 system: Surface cleaning. Flame treatment. Filler. Base coat. Varnish.

Production hall, several shots. Car body, several shots. Assembly of parts from the car roof, several shots. Car roof assemble, several shots. Door- and window mechanical system assembly, several shots. Interior mechanical system assembly, several shots. Trunkdoor assembly, several shots. Assembly car body, several shots. Assembly electric motor, several shots. Production line, several shots. Assambly electric motor / interior mechanic, several shots. Car body finalisation/inspection, marriage, several shots.

Production flow final assembly, several shots. General inspection, several shots.

Exterior shots plant Leipzig, several shots.