Funding: U.S. Department of Energy, Vehicle Technologies Office (VTO)
Collaborators: UD-CCM, Clemson University, Honda, LANXESS Tepex, Proper Tooling
This project evaluated thermoplastic composites for high-volume automotive closure systems, focusing on structural integration and manufacturability. The team designed and tested the first ultra-lightweight thermoplastic composite door structure, achieving a 45% weight reduction and 54% part count reduction relative to a conventional steel door.
Crash performance was validated through FMVSS 214 dynamic side-impact testing, demonstrating compliance with energy absorption and intrusion criteria. Process development emphasized compatibility with existing metal stamping infrastructure, enabling composite forming and assembly using current production tooling.
High-rate forming and joining methods were established for glass- and carbon-fiber-reinforced thermoplastic laminates, supporting cycle times suitable for automotive-scale manufacturing.
Awards and Recognition:
- DOE Vehicle Technologies Office Team Award (2022)
- SPE ACCE Most Innovative Prototype Part Award (2023)