Published 8/27/2024

Composites reinvent automotive

To celebrate National Composites Week, CW shares some of the latest innovations in automotive composites, from new process technologies to novel commercial applications.

Hannah Mason

Technical Editor, CompositesWorld

Composite materials have proven their advantages — especially their light weight, durability, corrosion resistance, and tunability compared to traditional metals — in a variety of automotive applications from high-end luxury vehicles to high-performance race vehicles to high-volume commercial applications.

Every day of National Composites Week, CW is highlighting content about a different end market in which composites are “reinventing” the industry and driving innovation. See yesterday’s “Composites reinvent aerospace, AAM and space” and follow along the rest of this week for more.

What are some of the latest ways composites are reinventing the automotive industry?

Expandable core for complex CFRP hood

Active core molding: A new way to make composite parts

In this August 2024 issue cover story, CW senior technical editor Ginger Gardiner explains Koridion expandable core material, which can be combined with induction-heated molds to make high-quality, complex-shaped parts in minutes with 40% less material and 90% less energy to unlock new possibilities in design and production.

One example use case of the technology is a Class A finish carbon fiber-reinforced polymer (CFRP) hood with integral air ducts and complex geometry (shown in article’s opening image).

Bio-inspired rollover cage

Carbon fiber, bionic design achieve peak performance in race-ready production vehicle

Porsche worked with Action Composites to design and manufacture an innovative carbon fiber safety cage option to lightweight one of its series race vehicles, built in a one-shot compression molding process.

Keys to success? A multi-tier, bio-inspired design approach.

Solar electric vehicles

SMC composites progress BinC solar electric vehicles

In an interview with one of Aptera’s co-founders, CW contributing writer Stewart Mitchell sheds light on the inspiration behind the crowd-funded solar electric vehicle, its body in carbon (BinC) and how composite materials are playing a role in its design.

Innovations in automotive body panels

Thermoplastic composites: Cracking the horizontal body panel nut

CW contributing writer Peggy Malnati sheds light on the history of automotive composite body panels — and their challenges — and explains a versatile sandwich panel technology developed to solve decades-long exterior automotive challenge.

Composites end market outlook

If you’re interested in a more comprehensive look at this year’s news and trends within the automotive composites industry, check out:

Composites end markets: Automotive (2024)

Recent trends in automotive composites include new materials and developments for battery electric vehicles, hydrogen fuel cell technologies, and recycled and bio-based materials.

Want more content and the latest news about composites technology used in the automotive industry, or in other end markets? Visit CW’s Markets page.

About National Composites Week

The goal of National Composites Week (NCW) is to celebrate and bring attention to the ways that composite materials and composites manufacturing contribute to the products and structures that shape the American manufacturing landscape today.

NCW takes place each year in the final week of August and celebrates a specific theme.

The 2024 theme was Composites Reinvent the World. See what companies and individuals shared on LinkedIn and read more from the CW editorial team: