How are composites used in automotive structures?

Within mid- and high-volume production vehicles, common composite applications include glass fiber-reinforced polymer (GFRP) leaf springs, suspension components, and drive shafts, sheet molding compound (SMC) body panels and frames; bulk molding compound (BMC) housings and support structures; and injection-molded thermoplastics for bumper frames, lift gates and seat structures. As electric vehicles (EV) become more prevalent on the road and in development by automotive manufacturers, new opportunities exist for composites and composite materials development. For example, a lighter-weight, composites-intensive vehicle is likely capable of driving for a longer range between charges. Battery enclosures present one large market opportunity in the EV market. Source: Composites end markets: Automotive

Why use composites for electric vehicle (EV) battery enclosures?

As the automotive industry rapidly electrifies its fleets, interest is growing among OEMs and battery module producers in using composite materials for battery enclosures — covers and trays that hold and protect the frames and battery cells themselves. There are many reasons for this, including the ability to reduce mass and stack tolerances, the fact that battery enclosures are multicomponent assemblies and poor impact performance of metals. In each of these areas, composite battery enclosures offer quantifiable benefits versus metals: lower mass, higher design freedom with greater space efficiency, faster assembly, no corrosion, greater durability and — with specific formulations — better flame resistance/fire containment. Source: Price, performance, protection: EV battery enclosures, Part 1

AUTOMOTIVE

Automotive

Orbital Composites licenses AMCM technology

Additive manufacturing compression molding (AMCM), co-developed with ORNL, combines robotic AM and continuous fiber technologies to revolutionize high-volume composites manufacturing.

Grace Nehls
Managing Editor, CompositesWorld

Mass Transit

Bio-inspired EV underbody panel developed by TPI Composites, Helicoid Industries

Composite underbody panel for battery pack protection, made of stacked multiaxial noncrimp fabric, will serve high-volume commercial and automotive markets.
#automation #electricvehicles

Mass Transit

SPE ACCE 2023 innovative parts competition is open for nominations

Any register conference participant may nominate original equipment, aftermarket or prototype composite parts for automotive, truck and UAM applications by July 30, 2023.

Automotive

SHD Composites backs Team BRIT disabled racing driver

Forty-one-year-old Paul Fullick seeks to make history with all-disabled racing drivers competing in the 24 Hours of Le Mans.

Automotive

Teijin Automotive Technologies supplies exterior body panels to Lotus Emira

The new premium sports car features exterior doors and panels made from Teijin Automotive Technologies’ compression molded TCA Ultra Lite material.

On Automotive

Orbital Composites licenses AMCM technology

Additive manufacturing compression molding (AMCM), co-developed with ORNL, combines robotic AM and continuous fiber technologies to revolutionize high-volume composites manufacturing.
#wingoftomorrow #space #continuousfiberAM

Bio-inspired EV underbody panel developed by TPI Composites, Helicoid Industries

Composite underbody panel for battery pack protection, made of stacked multiaxial noncrimp fabric, will serve high-volume commercial and automotive markets.
#automation #electricvehicles

SPE ACCE 2023 innovative parts competition is open for nominations

Any register conference participant may nominate original equipment, aftermarket or prototype composite parts for automotive, truck and UAM applications by July 30, 2023.

SHD Composites backs Team BRIT disabled racing driver

Forty-one-year-old Paul Fullick seeks to make history with all-disabled racing drivers competing in the 24 Hours of Le Mans.

Urban Air Mobility |

How Small Machine Shops Can Fight Supply Chain Problems

Supply chain disruptions are still presenting challenges in manufacturing. This article examines the effects on aerospace, automotive and medical industries. It also covers ways that machine shops can be successful securing work despite the challenges created by the supply chain.
#wingoftomorrow #space #medical

Videos / Podcasts

Mass Transit

3D Printed Cutting Tool for Large Transmission Part: The Cool Parts Show Bonus

March 23, 2023 - 12:30 AM EST

A boring tool that was once 30 kg challenged the performance of the machining center using it. The replacement tool is 11.5 kg, and more efficient as well, thanks to generative design.

Automotive

Teijin Automotive innovates core technologies for body panels

March 21, 2023 - 12:00 PM EST

The company’s latest Hexacore and Foam-A-Core products have been developed to meet needs for high impact, fast cycle times and low moisture absorption.

Wind/Energy

8 Transformations 3D Printing Is Making Possible

March 14, 2023 - 12:00 AM EST

Additive manufacturing changes every space it touches; progress can be tracked by looking for moments of transformation. Here are 8 places where 3D printing is enabling transformative change.
#wingoftomorrow #space #windblades

Mass Transit

How AM Enables Cobot Automation for Thyssenkrupp Bilstein (Includes Video)

March 01, 2023 - 12:32 AM EST

The shock absorber maker has responded to its staffing shortages through extensive use of collaborative robots. In-house 3D printing makes this possible by providing the related hardware needed to complete the cobot-automated cells.
#composites4-0 #automation

Energy Storage

Hexagon Purus opens new U.S. facility to manufacture composite hydrogen tanks

February 02, 2023 - 6:00 AM EST

CW attends the opening of Westminster, Maryland, site and shares the company’s history, vision and leading role in H2 storage systems.
#wingoftomorrow #space #windblades

Mass Transit

Reinventing the Wheel with Robot-Automated CNC Multitasking

February 02, 2023 - 12:00 AM EST

One race team discovers how to efficiently manufacture a new wheel nut design for the next-generation NASCAR stock car with the help of a CNC mill/turn and a built-in robot.
#automation

Natural Fibers

Lingrove plant-based ekoa composite featured in Hyundai Palisade concept vehicle

January 10, 2023 - 4:30 PM EST

Carbon-neutral biocomposite enables interactive doorspear with look and feel of wood while protecting trees, enabling transparency and capacitive touch for futuretech.
#sustainability

Glass Fibers |

Automotive chassis components lighten up with composites

Composite and hybrid components reduce mass, increase functionality on electric and conventional passenger vehicles.
#electricvehicles #feature

Peggy Malnati Contributing Writer

Automotive

Frasle Mobility launches composites-focused brand Composs

A production line in Brazil will produce composite automotive fender and tail light components for truck manufacturers.

Carbon Fibers

The T.33 Spider: Another carbon fiber masterpiece from Gordon Murray

The legendary performance designer-engineer believes in purity of execution, and the T.33 Spider shows that the approach still drives him.

Design/Simulation

Innoptus Solar Team uses Jetcam software to optimize production of solar vehicle

The world title-holding, Belgium racing team is producing its tenth composites-intensive solar car using Jetcam Expert nesting software.

Automotive

SPE announces first keynote for ACCE 2023 event

Joe Summers, commercial director at Airborne and managing director at Airborne UK, will speak about composites’ role in electrification, automotive/aerospace crossover and urban air mobility.
#wingoftomorrow #space

Automotive

Lacks Enterprises supplies 2023 Dodge Challenger with carbon fiber wheels

High-performance wheels, optional for the powerful Demon 170 muscle car, provide greater performance and weight reduction for an improved ride.

Glass Fibers

Classic Citroën vans reimagined using composites, AOC resins

Caselani Srl, with support from AOC Resins and designer David Obendorfer, retrofits close to 400 vans/year to meet modern needs and comfort for Type H car enthusiasts.

Automotive |

Pretend Your Audi EV Is the Prototype

While camouflage car coverings are meant to disguise surfaces of development vehicles, what Audi is doing to the RS e-tron will turn a whole lot of heads — and it is an electric vehicle that you can have in your own driveway.

Gary S. Vasilash Transportation Editor, Gardner Business Media