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Location: ACE Pavilion
Title: Cost-Effective Automotive Lightweighting
Description:
Award winners will be announced during a ceremony in the ACE Pavillion at 3:00 pm on Tuesday, September 10. Finalists will be available during these times to answer questions about their entry: Tuesday, September 10 | 3:30 PM – 4:30 PM Category - Manufacturing: Material and Process Innovation An automotive door structure was produced using WEAV3D’s patented continuous composite forming process, converting glass fiber and carbon fiber reinforced polypropylene unidirectional tapes into a FEA optimized woven, consolidated lattice that maximized performance in the critical load region, while minimizing material utilization in low load or trim-off regions. Polypropylene sheet was extruded using a conventional extrusion process and composite lattice was laminated to either side using a continuous double belt press. This laminated sheet was then thermocompression molded using an automated shuttle to first heat the sheet in an infrared oven before forming in a compression press with matched metal tooling. 5-axis waterjet cutting was used to trim the final part dimensions. This innovative approach achieved 50% cost savings, 23% weight savings, and 62% scrap reduction vs. the baseline component made using carbon fiber PA6 organosheet, while still meeting performance targets.
Wednesday, September 11 | 2:30 PM – 4:30 PM
Thursday, September 12 | 10:00 AM – 11:00 AM
Type: Award Entry
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