ANTEC 2024 - Cost-Effective Automotive Body Structures

WEAV3D has developed a novel hybrid-material approach, Rebar for Plastics®, that combines existing thermoforming, compression molding or injection overmolding processes with woven composite lattices formed from unidirectional thermoplastic tapes to produce high-volume, low-cost structural composites. The resulting structural panel exhibits high stiffness, strength, and ductility, equivalent or better than sheet metal, while offering weight savings of up to 65% compared to steel.

In partnership with Braskem, Altair, and the Clemson Composites Center, an automotive door structure originally developed in carbon fiber/PA6 organosheet was redesigned as a lattice reinforced polypropylene panel. This highly optimized structure achieved 20% weight savings and 50% cost savings vs. the original organosheet, while also reducing trim scrap mass by 63%. The FEA design process and experimental results will be presented, as well as a cost and performance comparison against the original organosheet design.

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Rebar for Plastics: Enabling Cost Effective Body Structures

In partnership with Braskem, Altair, and the Clemson Composites Center, an automotive door structure originally designed in carbon fiber/PA6 organosheet was redesigned utilizing WEAV3D’s Rebar for Plastics® design methodology, which leverages various micro-and macro-mechanical concepts to maximize performance and minimize cost in hybrid length-scale composites. This highly optimized structure achieved 20% weight savings and 50% cost savings vs. the original organosheet, while also reducing trim scrap mass by 63%.

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WEAV3D to present at CAMX 2023 in Atlanta, GA.


WEAV3D will be presenting two papers at CAMX 2023.

A Revised Finite Element Analysis Approach to Designs and Optimize Composite Lattice Reinforcements and Simulate the Mechanical Properties of Composite Lattice Reinforced Plastics Download the Abstract
Rebar for Plastics – A Novel Approach to Part Optimization with Hybrid Length-Scale Composites Download the Abstract

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Structural Enhancement of Sustainable Materials

The automotive industry has committed to increasing the use of sustainable materials in order to meet long term embodied carbon and circular economy goals. “Sustainable” materials are not clearly defined, but generally include natural fillers and fibers, polymers produced from bio-renewable feedstocks, and post-consumer and post-industrial recycled polymers. While bio-renewable feedstocks are largely equivalent to petroleum-based feedstocks in final polymer performance, natural fibers and recycled materials suffer from reduced and inconsistent mechanical properties compared to their synthetic or virgin alternatives. A significant portion of plastic components in the vehicle today are glass reinforced, presenting a substantial performance barrier to the adoption of natural fibers.

WEAV3D has developed a novel hybrid-material approach, Rebar for Plastics®, that dramatically improves the performance of sustainable materials, through a combination of natural fiber reinforced polypropylene (NFPP) mats and woven composite lattices formed from unidirectional tapes.

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Numerical Modeling of the Bond Behavior Between Thermoplastic FRP Lattice and Concrete

Replacing steel bars with fiber-reinforced polymer (FRP) bars is widely acceptable as a potential solution to eliminate the corrosion problem in reinforced concrete structures. This paper examines another option to resolve this problem, which utilizes a novel composite lattice material manufactured by WEAV3D Inc. The composite lattice is manufactured by weaving and bonding thermoplastic FRP tapes using an innovative lattice-forming process. Accurate representation of the bond between this lattice and concrete is needed to be able to utilize it in structural concrete elements. In this paper, numerical modeling of the bond between WEAV3D composite lattice and concrete is examined. The model predictions were validated using experimental data.

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Designing, Optimizing and Simulating the Mechanical Properties of Composite Lattice Reinforced Plastics With FEA


Recent advances in thermoplastic composite manufacturing have resulted in the development of hybrid overmolded composite structures, combining continuous fiber composites with injection or compression molded compounds; however, standard FEA techniques developed for isotropic materials and ply-based composites do not accurately capture the physical properties and material behavior of these hybrid materials.

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JEC Composites ConnectJune 1 to 2, 2021

JEC Composites Connect is the online meeting place for the global composites community.

This first JEC Composites Connect works as an online trade show with digital booths, a conference program, networking areas and JEC Group Innovation Programs.

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Investigating the Relationship between Fiber Length, Volume Fraction, and Mechanical Properties of Fiber-Reinforced Plastics

Within the current reinforced plastic manufacturing paradigm, a paradox exists; filled and long-fiber-reinforced plastics are cheap, but lack the mechanical properties needed to displace structural metals, while continuous-fiber reinforced plastics (“CFRP”) possess exemplary mechanical properties but cost too much to compete with inexpensive stamped steel. A revolutionary approach is needed to enable vehicle designers to bridge this gap and restart the growth of plastics in automotive structures.

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Automotive Lightweighting 2021June 14 to 15, 2021

Cost-effective Weight Reduction with Multi-material, Hybrid Length-scale Composites

Combining multi-material continuous fiber-reinforced lattices with long fiber overmolding enables lighter, stronger and less expensive structural composites
Novel composite manufacturing process enables high throughput production of multi-material and locally optimized composite lattices
FEA case study that illustrates expanded design space provided by multi-materials, hybrid length-scale composites

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Novel Approach to Thermoplastic Composite Production Enables Localized Design Optimization

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Braskem Takes Polypropylene to the Next Level of Performance in Partnership with WEAV3D® utilizing its Rebar for Plastics® Lattice Technology

This solution combines Braskem’s polypropylene sheets with WEAV3D lattice technology to address new structural and automotive applications requiring high-strength, lightweight material solutions.  Braskem to present its PP solutions with WEAV3D lattice technology at the 2023 SPE® TPO Global Automotive Conference in Detroit, October 1-4

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Natural-fiber reinforced thermoplastic composites have recently emerged as a lightweight, sustainable alternative to glass reinforced plastics for automotive interior applications such as package shelves, luggage compartment components, load floor and SUV cargo decks.

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Polymer concrete has traditionally been reinforced with steel rebar, but WEAV3D composite lattice technology has emerged as a superior reinforcement system that offers corrosion resistance and design freedom not possible with rebar cages. Unlike steel, our patented and patent-pending thermoplastic composite lattice forms an adhesive bond with the polymer concrete, enhancing the impact strength and other mechanical properties of the finished concrete part.

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Cable trenches play an important role in managing and distributing cables and wires in utility, rail and power applications. Oldcastle, a leading provider of building materials, supplies these durable components in the form of its polymer-based concrete trench systems. By using a patented material, these trenches offer exceptional H-20 loading at 25-percent less weight than traditional concrete. They also feature an excellent strength-to-weight ratio, reduce installation costs and provide a safer, more cost-effective option compared to concrete trenches.

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