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Summary: Carbon Fiber SMC and Glass Fiber SMC are molded together in a one step process. CFSMF is used to utilize locally re-enforce the door hinge area. Able to eliminate additional reinforcements and reduce the size of the door hinge reinforcement.
Weight Savings: 6 pounds
Cost Savings: N/A
Most Innovative Feature: Blending of Carbon Fiber SMC and Glass Fiber SMC to utilize locally the properties of Carbon Fiber for stiffness, strength and weight savings
Other Innovative Features: Able to eliminate additional reinforcements and reduce the size of the door hinge reinforcement. Able to reduce the cross section of windshield surround A-pillar while achieving greater stiffness.
Forming Process: Compression molding
First time process used?: Yes, first automotive application of carbon fiber SMC.
Previous Process Used: Steel stampings; steel tailor welded blanks; Racing and exotic applications use prepreg and wet-lay up carbon fiber composites not suitable for higher volume production
Tooling Innovations: N/A
New Material Developments: A blended hybrid joint was developed to co-mold Carbon Fiber SMC with Low Density Glass SMC to maintain strength and minimize dimensional issues.
Weight Savings: 6 pounds - door; 2 pounds - windshield surround.
Direct Cost Savings: 8% (Based on labor and investment vs. previous model year vehicle).
Indirect Cost Savings: N/A
Direct Consumer Benefit: Reduced door sag, increased door stiffness, reduced windshield header shake, cleaner windshield surround, styling (fewer joint lines, smaller sections, etc.).
Translates to other Vehicles?: Yes. This could be applied to high volume SMC structures to achieve the properties of carbon fiber (in local critical areas) while minimizing the cost
Safety Benefits: N/A
Environmental Benefits: None
Additional Info: The extensive use of nearly 18 pounds of carbon fiber materials on the 2003 Dodge Viper is a significant achievement for opening the doors to greater carbon fiber use in the automotive industry
