Is Carbon Already Obsolete for Non-Super Sports Cars?

Abstract

Few years ago, RTM-processed CFRP parts for automotive applications appeared to be the right choice for e-mobility. Today it becomes clearer that e-mobility does not necessarily mean lightweight in terms of CFRP. Tesla Model X, Jaguar I-Pace, Faraday FF-91 and even VW eGolf show that e-mobility will also work without lightweight design from ground up. Bigger batteries might do the job as well. This question remains: Is carbon already obsolete for non super sports cars? Lightweight is not the only benefit of composites. Interlaminar integration of functions can be another one. Still there are challenges in cost, process robustness and cycle times. Within DLR’s Next Generation Car- project (NGC), solutions for these challenges are investigated by developing a quick and inexpensive process for sandwich parts with integrated functionality. The approach is using expensive carbon fibres only where they provide the most benefit, getting rid of huge investment cost for tools and machines and creating dual uses wherever possible. Along with a highly automated but still flexible production line there might be new chances for CFRP parts even in smaller production rates with reasonable efford. This presentation will point out technical solutions as well as first estimations concerning economics of such a process regarding recurring and non recurring cost and possible cycle times. A discussion about its industrial use, especially by small and medium sized companies will be greatly appreciated.