Engineering Materials

New Composites Institute Chief Talks About Grand Challenges

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Jerry dycus
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Talk or build?
Jerry dycus   1/31/2015 10:46:31 AM
These are already achieved with present tech.  The problem is getting big auto to build them.

The i3 process for it's CF body is 20 yrs old.

Yet lower tech like hand layup can produce high quality composite parts sets at very low costs. For instance with a good production line set up a 4 person crew could make a car set including door, hood, hatch, etc in 1 hour.

With more automation, 1 every 10 minutes or 1200/line/shift 300days/yr.  X's how  many lines you need for your production level .

These production lines cost 10% of a steel body production line and you don't get the doors, etc or the 7 metal coatings and paint, body work steel car bodies need.

These weigh about 350lbs and cost $2/lb average so labor and materials is under $1k/car set done in medium tech composites 2x's as strong as a steel version. And no CF as it's a terrible car material many times the price with little benefit.

And the i3 shows how bad it canbe done as heavier than other steel subcompacts it should be 60% of the weight of like the Visio.M or the Toyota 1/x, weighing nder 1k lbs.

But the fact is FG and kevlar type composite are better in crashes by a large amount with only a 5% weight pentalty at 10-20% of the cost.

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