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Summary: First application of carbon fiber on a large body exterior/chassis component using a production capable process. Consolidates 15-20 brackets, supports the entire front end of car body and attachments for over 34 components; Unpainted, molded in-color fender supports make up the underhood appearance closeout for the engine compartment.
Weight Savings: 40 pounds
Cost Savings: N/A
Most Innovative Feature: First application of Carbon Fiber on a large body exterior/chassis component using a production capable process (compression molded carbon fiber SMC)
Other Innovative Features: Consolidates 15-20 brackets; Provides dimensional reference and supports the entire front end of car body; Provides attachments for over 34 components; Fender Supports also make up the underhood appearance closeout for the engine compartment and are unpainted, molded in-color black
Forming Process: Compression molding
First time process used?: Yes
Previous Process Used: Steel stampings, brackets and hardware. Previous carbon fiber automotive applications for large body structures have been prepreg and wet lay-up (processes not suitable for volume production) only on exotic or racing vehicles.
Tooling Innovations: N/A
New Material Developments: First use of Carbon Fiber SMC in automotive application
Weight Savings: 40 pounds
Direct Cost Savings: Investment savings is estimated to be 70-80% less than conventional front end structures.
Indirect Cost Savings: N/A
Direct Consumer Benefit: Increases first bending mode at A-Pillars by 3.1 Hz for reduced body and header shake.
Translates to other Vehicles?: Yes. This material and type of structure could be applied to high volume programs up to approximately 150,000/year on one set of tooling.
Safety Benefits: N/A
Environmental Benefits: None
Additional Info: Weight savings are realized by thin wall compression molding (2.0mm). This extensive application of carbon fiber is a significant achievement for greater future use of carbon fiber in the automotive industry.
