Compared with traditional epoxy-based thermosetting composite materials, thermoplastic composite materials have many advantages such as fast molding, good toughness, no need for low-temperature storage, and recyclability.
Continuous fiberglass reinforced thermoplastic (CFRT) is recyclable, has high specific strength and stiffness, good corrosion resistance, impact resistance, heat resistance, low cost and design flexibility. CFRT has huge applications in automotive lightweight design, can replace some metal materials and high-end polymer materials.
Learn more about Continuous Fiber Reinforced Thermoplastic Composite Sheets.
Body Structural Parts
- Seat bottom
The seat pan, which is overmolded from a continuous fiber-reinforced thermoplastic laminate, is 45% lighter than traditional materials.
- Rear seat shells
The lightweight rear seat shell in composite material design is 45% lighter than steel plates.
- Seat back frames
A thermoplastic composite material system is used to replace metal. Its weight is reduced by up to 20% compared with traditional seats. The thin and light design adds more knee room for second-row passengers.
- Front-end module inserts
Continuous fiber-reinforced thermoplastic composites are approximately 50% lighter than inserts made from sheet steel. Additionally, CFRT insert areas can withstand higher stresses.
- Lightweight A-pillar
The strength of the continuous fiber-reinforced thermoplastic composite ensures that the A-pillars perform as well as previous high-strength steel tubes and can withstand rollovers, and it reduces weight.
- Door base plates
The continuous fiber composite material solution is used to replace the steel solution, and a new hybrid production process (molding + injection molding) is used to realize the manufacturing and production of thermoplastic composite door base plates. Compared with steel and long fiber PP door systems, thermoplastic composite door systems can effectively reduce weight by up to 30%.
- Child seat headrests
The weight of the forehead pillow using CFRT material is reduced by 30%, but it does not affect its excellent crash performance. The production process has also been simplified as the number of parts has also been reduced.
Chassis Structural Parts
- Engine bottom cover
The engine underguard designed with continuous fiber thermoplastic composites is more than 60% lighter than the corresponding parts made of steel, and is more than 20% lighter than the corresponding aluminum parts.
- Suspension control arms
Suspension control arms made of continuous fiber thermoplastic composites have the same functional and mechanical properties as those made of metal, but are 50% lighter.
- Car suspension system
Continuous fiber thermoplastic composites are easy to process, cost-effective and recyclable, and have great potential in automotive lightweight applications.
- Brake pedals
It weighs only about half of traditional steel pedals and can be mass-produced in a single molding process, making it extremely cost-effective.
Collision Parts
- Side door anti-collision beams
Using this material reduces component weight by 40% compared to ultra-high-strength steel (UHHS), while absorbing more impact energy than similar products made from metal and short glass fiber polymers .
Wheels
Wheels made from continuous fiber-reinforced thermoplastic composites meet stringent safety and performance requirements.
