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FINALIST |
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(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
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| Description: |
Carbon Fiber Decklid |
Model: |
Focus FCV |
| OEM: |
Ford Motor Company |
Model Year: | 2007 |
| System Supplier: |
Multimatic Technical Centre |
Generic Resin Type: |
Epoxy |
| Molder/Processor: |
Multimatic Technical Centre |
Resin Trade Name: |
MTM49 |
| Toolmaker: |
Multimatic Technical Centre |
Grade: |
MTM49-3 |
| Material Supplier: |
Advanced Composites Group |
Other Innovative Features: |
Structural class A panel assembly, with low cost tooling investment vs. aluminum option |
| Most Innovative Feature: |
60% mass reduction relative to the steel baseline decklid |
Forming Process: |
Vacuum bag / autoclave cure |
| Weight Savings: |
60% vs. production steel baseline |
First Time Process Used? |
First North American OEM carbon fiber decklid |
| Cost Savings: | Higher component cost was offset by low investment tooling and additional mass savings not achievable with aluminum solution | Previous Process: | Replaced the production 3pc stamped steel assembly; lower cost and lighter weight alternative to an aluminum solution |
| Cost Avoidance: |
75% cost avoidance of low volume stamping tools for aluminum panel |
Transferable to Other Vehicles: | Yes; other applications would include class A body panels and structural components for niche volume vehicles |
| Benefits to Consumer: | |||
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Mass reduction to offset mass of fuel cell system increases fuel
economy, saving customer operating costs by increasing vehicle range |
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| Method Comments: | |||
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Sandwich panel construction to reduce bondline readthrough on
structural panel |
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| Innovations/Improvements: | |||
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Low investment one-sided carbon fiber tooling |
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| Safety Improvements: | |||
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Supported H2 storage venting requirement in addition to all current requirements |
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| Environmental Comments: | |||
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Reduced vehicle weight to enable demonstration of fuel cell technology |
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| Additional Comments: | |||
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The decklid is the first North American OEM application of a
lightweight carbon fiber composite to structural class A decklid.
The decklid was completely engineered using CAE methods and physical
testing to meet all OEM DVP&R requirements |
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| Summary: | |||
| This structural, Class A sandwich panel assembly is 60% lighter than the 3-piece stamped steel assembly it replaced, which helps offset the mass of the vehicle’s fuel-cell system for better vehicle range and lower operating costs. It was produced via vacuum bag / autoclave cure using one-sided carbon fiber tooling, which is 75% less costly than the aluminum benchmark. | |||
