SPE ACCE 2024 - Cost Effective Thermoplastic 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-rate, cost-effective 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. A case study covering design, manufacturing, and testing of this innovative thermoplastic composite structure will be presented, showcasing 20% weight savings and 50% cost savings vs. organosheet, while also reducing trim scrap mass by 63%. This presentation will also discuss how OEMs and Tier suppliers can adapt this cost-effective lattice-reinforced approach to other vehicle components and molding processes.