Reducing The Cost Of Multi Material Joining & Forming And Maximising Quality Assurance
February 24-25, 2016 - Detroit, Michigan, USA
http://www.global-lightweight-vehicle-manufacturing.com/
The 3rd Annual Lightweight Vehicle Manufacturing Summit 2016
1. 3RDLIGHTWEIGHTVEHICLEMANUFACTURING2016
JOINING,FORMING&QUALITYASSURANCESUMMIT
www.global-lightweight-vehicle-manufacturing.com
Register By Friday
October 30, 2014
• Upset Protusion Welding
• Friction Stir Welding
• Magnetic Pulse Technology
• Resistance Spot Welding For Aluminum
• Robotic Friction Stir Welding
• Structural Bonding For Aluminum And Steel
• Manufacturing Quality Control
• Corrosion Mitigation
The Most Practical Automotive Summit Bringing Insights Into The Latest
Breakthroughs In High Volume Cost Effective Vehicle Manufacturing
MITIGATE CORROSION FOR MIXED MATERIALS: Clarifying Which Corrosion Mitigation
Techniques Are Being Effectively Used By OEMs To Maximize Joints Durability
ACHIEVE EFFECTIVE MATERIAL CHARACTERIZATION: Evaluating Properties Of The New
Grades Of UHSS, Aluminum And Composites To Determine Their Influence On The
Selection Of Multi-Material Joining And Forming Technologies
KEEP JOINING COSTS TO MINIMUM: Comparing The Cost Vs. Resistivity Performance For
Laser Welding, Resistance Spot Welding And Structure Bonding For Dissimilar Materials
Such As Diverse-Strength Steel, And Carbon Fiber Composites
SHORTEN PRODUCTION CYCLES: Learn How OEMs Are Implementing The Very Latest
Joining And Forming Methods To Drastically Reduce Production Cycles
MANAGE COMPOSITE PAINTABILITY: Optimizing Composites Properties Through The
Processing And Forming To Maximize Parts Paintability
EVALUATING REPAIRABILITY STRATEGIES: Assessing Joint And Material Reparability To
Better Understand Vehicle Parts Lifecycle And Repair Costs
24 - 25 February, 2016 | Detroit, Michigan
Organized By:
CO-SPONSORS:
SAVE UP TO 20% WITH GROUP DISCOUNTS
CALL FOR RATES: (1) 800 721 3915
Mark Voss
Engineering Group Manager Body
Advanced Technical Works
General Motors
Stephen Logan
Sr.Technical Specialist -Lightweight Metals and Manufacturing
Projects - Advanced Development Engineering
FCA US LLC
Khaled W Shahwan
Fellow AIAA, Innovation & Advanced
Development Engineering (ADE)
Fiat Chrysler Automobiles
Dr. Surender Maddela
Sr. Researcher, Lightweight
Material Processing
GM R&D
Francois Nadeau
Technical Leader Aluminum Assembling
Technologies
National Research Council Canada
Joy Forsmark
Technical Expert Light Cast Metals
Ford Motor Company
Danick Gallant
Research Agent
Aluminum Technology Centre (NRC)
The Latest OEM Case Studies On:
Implementing Advanced Lightweight Materials Joining
Techniques,Corrosion Mitigation And Quality Assurance To
Enable Maximum Resistivity And Performance For
Lightweight Multi-Material Joints
Including Diverse-Strength Aluminum, Steel, Magnesium And Composites
At Lower Costs And Shorter Production Cycles
Insights From OEM Manufcturing Experts
2016 HEADLINE SPONSOR
NETWORKING BREAK SPONSORS:
2. www.global-lightweight-vehicle-manufacturing.com (1)8007213915 info@american-business-conferences.com
Good mix of talks and speakers and there was more
technical content than I expected. This was a pleasant
surprise. Food, resources and media were excellent
Technical Fellow
General Motors
Manufacturing High Performance Parts Quicker,
At A Lower Cost
Successfully securing its place as one of the most sought after manufacturing
conferences within the automotive industry the GALM Series Lightweight
Vehicle Manufacturing 2016 Summit is returning back in its 3rd year with a
brand new agenda that will focus on resistivity and quality assurance.
The program has been completely revamped to address the most pressing
issues relevant to the OEMs today.
To address the raising concerns for OEMs with the ultimate goal of lowering
costs and shortening production cycles, the 2016 program will look at brand
new topics including advanced corrosion mitigation for mixed materials,
ways to keep joining costs to minimum, managing composites paintability
and evaluating reparability strategies alongside the all important ones of
optimizing mixed material joining performance and enhancing formability of the
new materials cost effectively.
Enabling Maximum Joint Resistivity And Performance
With the increasing pressure on the automotive OEMs to reduce emissions via
wider adoption of lightweight materials, the GALM Manufacturing is returning
to Detroit in February 24-25, 2016 to address the issues that continue to plague
the automotive industry.
Specifically designed for manufacturing experts, the GALM Series Lightweight
Vehicle Manufacturing 2016 Summit continues to lead the industry providing
innovative solutions to challenges faced across every OEM. Regardless of
which material companies are moving towards the challenges remain the
same – how to produce lightweight vehicles cost effectively on the shortest
production cycle.
SAVE UP TO 20% WITH GROUP DISCOUNTS
CALL FOR RATES: (1) 800 721 3915
Comprehensive Joining Analysis
Detailed case studies of aluminium-aluminium welding,
aluminium-steel welding, steel-steel welding and even an
evaluation of magnesium-aluminium bonding to measure
it’s viability for a mass production environment
Quality Assurance at all Stages
Sessions explore all major aspects of the manufacturing
process, but with a constant focus on quality. From
assessing the life expectancy and durability of joining
strengths, to the manufacturing standards to ensure
material integrity and even the comparison of results
for varying corrosion mitigation techniques, quality is
examined on a forensic scale.
Mass Production of Composites
A comprehensive analysis of different forming techniques
for composites in advanced shapes, in order to show if an
OEM can mass produce them on a scale where the high
level of volume is matched only by the high level of quality.
Paint & Finish
Meticulous evaluation of industry wide paint issues,
including ensuring maximum weld paintability in metals,
and measuring thermal expansion properties to negate
potential paintability complications.
Reasons To Attend
A culmination of thought
leaders from OEMs, suppliers
and innovators
Chief Operating Officer
Local Motors
Venue Information
Detroit Marriott at the Renaissance Center
400 Renaissance Drive
Detroit, Michigan
USA
3. DAY 1: ADVANCED JOINING TECHNIQUES FOR DISSIMILAR METALS SUCH AS DIFFERENT
STRENGTHS OF ALUMINUM AND STEEL, INCLUDING LASER WELDING, ROBOTIC FRICTION
STIR WELDING AND MAGNETIC PULSE TECHNOLOGY
Day 1
Wednesday February 24, 2016
8.30 Chair’s Opening Remarks
Joining Methods For Diverse-Strength Metals
Assessing Laser Welding And Resistance Spot Welding For
Aluminum And Steel Parts With Varied Strengths To Identify
Which Joining Technology Is Helping OEMs Achieve Better
Quality Results At Lower Costs
UPSET PROTRUSION JOINING
8.45 Evaluating The Upset Protrusion Joining (UPJ)
Method To Join Magnesium Castings To Dissimilar
Metals
• Discussing the challenges of joining magnesium castings to
dissimilar metals
• Establishing benchmark joint performance results for
magnesium die-castings to aluminum sheet material using
the SPR process
• Introducing the UPJ process for joining magnesium castings
to dissimilar metals to improve the cycle time
• Discussing UPJ joint performance results and comparing to
benchmark SPR joint performance
StephenLogan,Sr.TechnicalSpecialist-LightweightMetalsand
ManufacturingProjects-AdvancedDevelopmentEngineering,FCA
9.15 Question & Answer Session
FRICTION STIR WELDING
9.25 Investigating Friction Stir Welding Of Aluminum To
Steel For Armored Vehicles
MartinMcDonnell,Mechanical/WeldEngineer,U.S.Army
Tank,Automotive,Research,Development,And
EngineeringCenter(TARDEC)
9.55 Question & Answer Session
MAGNETIC PULSE TECHNOLOGY
10.05 Leveraging Magnetic Pulse Technology For
Advanced Manufacturing Processes in Automotive
• Understanding Magnetic Pulse Technology and what is has
to offer
• Examining the application of Magnetic Pulse Technology for
joining of dissimilar material and for forming application
• Understanding how the technology can be applied to car-
body related joining and parts forming tasks
Jean-CharlesBoutin,BusinessDevelopmentDirector,Bmax
10.15 Question & Answer Session
10.20 Morning Refreshments In Exhibition Showcase Area
Sponsored By Bmax
RESISTANCE SPOT WELDING FOR ALUMINUM
10.50 Joining Simulation: Using Innovative Simulation
Software To Achieve Higher Accuracy For Resistance
Spot Welding Aluminum In Terms Of Its Brittleness
• Comparing the cost of resistance spot welding for aluminum
vs. self-pierced rivets to determine differences in capital
costs for each method
• Assessing strategies for increasing the resistivity of 700-500
aluminum within resistance spot welding to maximize
performance whilst minimizing costs
• Hearing how an OEM is monitoring spot welds with process
control systems such as resistance checkers and DC
transformers
11.20 Question & Answer Session
MULTI MATERIAL JOINING
11.30 Evaluating Different Joining Techniques To
Understand Which Can Deliver The Most Cost And
Time Effective Solution For Mixed Material Joining For
Lightweight Vehicles
• Evaluating the optimal joining techniques for when you have
steel, aluminum and carbon fiber in the same car
• Determining what can be done at the level of joining to
prevent corrosion when dissimilar materials come into
contact
• Determining which joining techniques offer the optimal
time- and cost-efficiencies for mixed material applications
• Overcoming the key challenges of optimizing mixed material
joining techniques at mass produced scales
CraigCowan,President,RB&W
11.45 Question & Answer Session
ROBOTIC FRICTION STIR WELDING
11.50 Showcasing Robotic Friction Sir Welding
Developments For The Automotive Industry
• Presenting FSW application with a particular focus in
the control capabilities of the robotic system and specific
requirements driven by the application
• Understanding a novel approach for a friction stir spot and
stitch device, presented as a leverage of the linear robotic
system
• Highlighting the benefits of using an external heat source
combined with friction stir welding to minimize forces in
aluminum extrusions and increase joint resistance in Al/
Steel joining
• Benchmarking automotive and railcar industry applications
focusing on extrusion’s tolerances as well as self-clipsed
extrusions
FrançoisNadeau,TechnicalLeaderAluminumAssembling
Technologies,NationalResearchCouncilCanada
12.20 Question & Answer Session
12.30 Lunch In Exhibition Showcase Area
Joining Methods For Mixed Materials And Composites,
UHSS Stamping And Meeting Material Supplies
Evaluating Innovative Joining Methods For Mixed Materials
& Composites, Minimizing Costs & Weight Of UHSS Parts
Utilizing Advanced Stamping Method & Scrutinizing Aluminum
Supply Chain Potential
SessionChair:Dr.SurenderMaddela,Sr.Researcher,
LightweightMaterialProcessing,GMR&D
STRUCTURAL BONDING FOR ALUMINUM AND STEEL
1.30 How An OEM Has Used Bonding For Structural
Aluminum-Steel Parts: Measuring Performance Against
Process Cycle Times And Effectiveness
• Examining heating and cooling cycles for aluminum-steel
structural parts bonding to gauge parts resistivity
• Comparing costs vs. results for mechanical and chemical
bonding for aluminum-steel parts
• Assessing the response of structural bonding for aluminum-
steel parts to coating to ensure maximum quality
• Learning from experiences on structural bonding in the
aerospace industry to understand how to implement
aluminum-steel structural bonding in a mass production
environment
• Understanding the impact of high temperatures on
materials in bonding for aluminum-steel structural parts to
minimize imperfections
SessionChair:Dr.SurenderMaddela,Sr.Researcher,
LightweightMaterialProcessing,GMR&D
2.00 Question & Answer Session
JOINING TECHNOLOGIES WITH AND WITHOUT
FASTENERS
2.10 Using Various Joining Technologies Other Than
Welding For Aluminum And Mixed Materials To Evaluate
Their Performance
• Explaining how each joining process works to understand
their application potential based on material type and
thickness
• Discuss joining dissimilar materials with adhesive in
combinations with these joining technologies to evaluate
their effectiveness
• Showing current applications and discussing the advantages
and limitation of each process: Clinching, Clinch Rivet,
Punch Rivet, Vario Point Clinching and Special Insertion
Fasteners
TroyWaldherr,SalesManager,TOXPressotechnik-North
America
2.25 Question & Answer Session
MIXED MATERIAL BONDING
2.30 Presenting Practical Considerations Of Mixed
Material Bonding To Support Lightweight Vehicle
Design & Manufacturing
• Review of the practical considerations required in the
adhesive joining of mixed material, used in support of the
vehicle structural lightweighting initiatives
• Examination of the design and process related difficulties in
the integration of conventional structural adhesives toward
mixed material bonding requirements
• Introduction of a new generation of structural adhesives
developed to address emerging trends and requirements,
with examples of current applications
PhilipE.Weber,VicePresident,ProductEngineering&
TechnicalServices,IndustryandAutomotive,Sika
Corporation
2.45 Question & Answer Session
BONDING: COMPOSITES AND ALUMINUM
2.50 Identifying Key Challenges In Bonding For Carbon
Fiber And Other Composites With Aluminum And Steel
Frames To Understand How To Significantly Optimize
Performance
• Evaluating early experiences on composite-aluminum
bonding to understand what are the key challenges
• Understanding how transferable lessons on carbon fiber-
aluminum joining can be implemented in small-scale
manufacturing
• Assessing innovative bonding methods for carbon fiber-
aluminum to identify how to maximize joining strength and
durability
• Looking at different assembly strategies and techniques
that could be adopted for composites bonding to allow the
assembly output to reach medium volume of output at
minimum costs
3.20 Question & Answer Session
SELF PIERCING RIVETS (SPR)
3.30 Exploring Henrob Self-Pierce Riveting (HSPR) To
Understand Its Application On Aluminum Intensive And
Mixed Material Programs
• Explaining what SPR is to understand how it can be allied in
lightweight automotive production
• Learning about current status of materials being joined
with HSPR in BIW / CIW applications and the trend in the
near future
• Clarifying what is critical to the application, and optimization
of SPR when considering an aluminum intensive or mixed
metal program
DaveBaker,BusinessDevelopmentManager-NAAutomotive,
HenrobCorporation
3.40 Question & Answers
3.45 Afternoon Refreshments In Exhibition Showcase Area
Sponsored by Henrob Corporation
GENERATION 3 STEEL
4.15 Giving An Overview of The United States Steel
Automotive Solutions to Light weighting
BernhardHoffmann,VPEngineeringandProductDevelopment,
AutomotiveSolutions,USSteel
4.30 Question & Answer Session
4.35 Chair’s Closing Remarks
4.45 - 5.45 Networking Drinks Reception In Exhibition
Showcase Area
www.global-lightweight-vehicle-manufacturing.com (1)8007213915 info@american-business-conferences.com
4. DayChair:Dr.KhaledW.Shahwan,FellowAIAA,
Innovation&AdvancedDevelopmentEngineering
(ADE),ChryslerTechnologyCenter,FCA
9.00 Chair’s Opening Remarks
ENSURING MAXIMUM JOINING QUALITY
Outlining The Latest Advancements In Process Control For
Aluminum-Steel Joints, Life-Cycle Evaluation For Welds And
Corrosion Mitigation For Aluminum-Steel And Magnesium To
Identify Key Strategies For Ensuring Maximum Part Resistivity
And Durability
BREAKFAST BRIEFING: MANUFACTURING QUALITY
CONTROL
9.10 Utilizing Hand Held XRF (X-Ray Fluorescence)
To Confirm The Chemical Composition Of Aluminum
And Other Alloys to Ensure Quality Control Over The
Materials Throughout Automotive Manufacturing
• Including the role of XRF to accurately measure the
thickness of electro plating, passivation and conversion
coatings
• Assessing the compatibility of XRF to measure the chemical
composition of High Strength Steels, Magnesium and
Titanium alloys
MarkLessard,BusinessDevelopmentManager,ThermoFisher
Scientific
9.20 Question & Answer Session
CORROSION MITIGATION
9.25 Examining Corrosion Mitigation Strategies For
Cast Magnesium and Mixed Metals Joints
• Presenting the results from the USCAR project on
Magnesium front end Research and Development
• Exploring strategies involving conversion coatings and
e-coating in conjunction with different joining techniques
and Mg/Al/Steel combinations
• Investigating structural adhesives and the use of body shop
sealant
• Presenting the results of OEM cyclic corrosion testing for
different strategies
Dr.JoyH.Forsmark,TechnicalExpert,LightCastMetals,
FordMotorCompany
9.55 Question & Answer Session
QUALITY ASSURANCE: ALUMINUM-STEEL JOINING
10.10 Implementing Process Control Systems To
Achieve Higher Resistivity Levels In Aluminum-Steel
Joining Methods
• Evaluating methods for verification of aluminum-steel joint
quality to ensure maximum joining life-cycles
• Implementing process control systems for resistance spot
welding such as resistance checkers to maximize joints
quality
• Monitoring resistance spot and laser welding processes to
measure production cycles more accurately
• Analyzing how sheet clamps create air gaps within diverse-
strength aluminum sheets to determine whether alternative
equipment set-ups would solve this
• Hearing how an OEM is monitoring spot welds with process
control systems such as resistance checkers and DC
transformers
SessionChair:Dr.KhaledW.Shahwan,FellowAIAA,
Innovation&AdvancedDevelopmentEngineering
(ADE),ChryslerTechnologyCenter,FCA
10.40 Question & Answer Session
CLINCHED FASTENERS
10.50 Optimizing The Clinched Fastener/Clinched
Component Design And Interface Required For
Reduced Mass Applications
• Optimizing the clinched fastener/clinched component
design and interface to meet requirements for reduced
mass applications
• Showcasing improvements in the existing product lines and
presenting new products (Light - Weight Nut and Aluminum
clinched fastener element) to allow better joint performance
in harder and less ductile material
JimErhardt,President,Rifast
11.00 Question & Answer Session
11.05 Morning Refreshments In Exhibition Showcase Area
Sponsored by Rifast
LIFE-CYCLE EVALUATION: NUMERICAL SUMULATION
OF GALVANIC CORROSION
11.35 Understanding Numerical Simulation of Galvanic
Corrosion as a Decision Support Tool for the Design of
Aluminum to Dissimilar Materials Assemblies
• In-service exposure of galvanic couples (Al-Stainless Steel,
Al-CFRP, Al-High Strength Steel), including continuous
monitoring of galvanic currents
• Using advanced electrochemical characterization of
materials for modelling
• Developming novel laboratory method for investigation of
real galvanic corrosion risks (on the basis of field results)
• Mitigating galvanic corrosion issues on the basis of
numerical simulation: selection of materials, geometry &
fasteners
DanickGallant,ResearchAgent,AluminumTechnology
Centre(NRC)
12.05 Question & Answer Session
PANEL DISCUSSION: REPAIRABILITY
12.15 Assessing Joints And Material Reparability To
Better Understand Vehicle Parts Lifecycle And Map Out
Repair Costs & Devise Repair Strategies
• Identifying which repairs are possible to determine
whether parts can be sectioned relative to joining, welding
or bonding types
• Understanding main guidelines for repair to minimize
process lifecycles and costs
• Streamlining methods for identifying damage levels on
lightweight materials
• How can different strength-levels of aluminum be repaired
effectively?
PanelChair:Dr.KhaledW.Shahwan,FellowAIAA,
Innovation&AdvancedDevelopmentEngineering
(ADE),ChryslerTechnologyCenter,FCA
12.45 Networking Lunch in the Exhibition Showcase Area
High Volume Composite Forming
Forming And Processing Technologies That Are Being
Implemented For Carbon Fiber And Other Advanced
Composites To Determine Which Of These Can Be Adopted In
Mass Production Environments
ADVANCED COMPOSITES FORMING
1.45 Evaluating Different Forming Methods For Carbon
Fiber, Glass Fiber And Other Composites For Advanced
Shapes To Determine Whether It Is Economically Viable
To Apply Them In Mass Production
• How an OEM is performing advanced forming analysis
for composites to ensure high quality parts that will be
compatible with high production rates facilities
• Comparing injection molding vs. hydroforming vs.
compression molding for carbon fiber from a cost vs. benefit
standpoint to determine which forming method can ensure
shorter production cycles at lower costs
• Assessing the impact of processing temperature on
composites forming to ensure maximum quality for
composites forming
• Understanding the role of the supplier in speeding up the
production of carbon fiber composites to secure parts
availability for mass production
• Examining performance, paintability, mechanical properties
and appearance of advanced composites and their ability to
be bonded and fastened
• Evaluating innovative methods to inject, secure and set resins
for composites to achieve shorter production cycle times
2.15 Question & Answer Session
FLOW DRILL FASTENING
2.25 Giving An Overview Of The Specificities Related
To The Use Of The Flow Drill Screws In Lightweight
Assembly To Optimize Production Process
GeneSimpson,VicePresidentofQuality&Engineering,
SemblexCorporation
2.35 Question & Answer Session
2.40 Afternoon Refreshments In The Exhibition Showcase
Area Sponsored By Semblex Corporation
Enhancing Composite Processing And Maximizing
Part Paintability
Understanding How To Enhancing Composite Processing And
Maximize Part Paintability
COMPOSITE PROCESSING
3.10 Standardizing Formats For Raw Material
Processing To Mitigate Temperature Effects On
Composite Materials In Terms Of Appearance
Imperfections And Bonding Performance
• Establishing manufacturing standards for composite
processing to ensure maximum material quality and
reduce costs
• Evaluating methods to process advanced composites such
as carbon fiber while maintaining joint strength and part
performance requirements
• Assessing the heating and cooling cycles for raw composite
materials in terms of the systems the materials are stored
in and how they are pumped through from the container to
the jobs
• Testing resin, pigment, norylburyloxetate and acetone levels
on raw materials ahead of time to optimize composite
processing
3.40 Question & Answer Session
COMPOSITES PAINTABILITY
3.50 Managing Composite Properties Through
Processing And Forming To Maximize Part Paintability
• Measuring thermal expansion properties of the different
composite materials to prevent paintability issues for
composite parts
• Optimizing the fluidness and cleanliness of composite panel
surfaces to ensure optimum paintability and ultimately
reduce cost
• Understanding how suppliers and OEMs are using electro-
static primers to achieve maximum color coding accuracy
and ensure color coherence
4.20 Question & Answer Session
4.30 Chair’s Closing Remarks And End Of Conference
Day 2
Thursday February 25, 2016
DAY 2: CORROSION CONTROL, QUALITY ASSURANCE, COMPOSITE FORMING MAGNESIUM,
CASTING AND PAINTABILITY
www.global-lightweight-vehicle-manufacturing.com (1)8007213915 info@american-business-conferences.com
Concept directly in line
with challenges I face everyday.
Great to hear other OEMs/Tiers
speaking about these issues
Advanced Material Research
Honda R&D Americas
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