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Manufacturing Composite Structures (November 1994)

Automotive Composite Structures: Development of High-Volume Manufacturing Technology

Develop a composites-manufacturing process called Structural Reaction Injection Molding into a cost-effective means of producing large automotive structural parts such as the box of pickup trucks.

Sponsor: Automotive Composites Consortium c/o Daimler Chrysler (formerly General Motors)

c/o USCAR, Fairlane Plaza South, Suite 100
330 Town Center Drive
Dearborn, MI 48126
  • Project Performance Period: 3/1/1995 - 2/28/1997
  • Total project (est.): $6,680,000.00
  • Requested ATP funds: $3,273,000.00

The objective of the proposed research is to develop and demonstrate the full-scale process capability of Structural Reaction Injection Molding (SRIM) on a large, complex automotive composite structure that meets all the performance requirements; and to define parts and assemblies that can be manufactured in high volume, and processed/manufactured economically and consistently. The successful integration of innovative technical approaches to address and overcome associated "high risk" issues in design, crash energy management, joining, tooling and molding will be demonstrated on a generic all-composite pickup truck box and tailgate assembly that has been selected as the focus to leverage the SRIM process developments. The ACC proposes to achieve this objective by demonstrating a 'designed for composites' vehicle prototype that is manufacturable and meets performance criteria 'typical' of automotive product requirements. By vertically integrating, this landmark, precompetitive partnership of the U.S. domestic automakers also will develop a multi-tier production supplier base capable of manufacturing large polymeric composite parts in high volume, at low cost. for future generations of lightweight, fuel-efficient, cost-competitive passenger/cargo-carrying type vehicles planned by each individual automaker. Members of the consortium include Chrysler Corporation, Ford Motor Company, and General Motors.

For project information:
Scott Fosgard, (313) 248-4298

Active Project Participants
  • Daimler Chrysler Corporation, Organic Materials Engineering (Auburn Hills, MI)
    [Original, Active Member]
  • Ford Motor Company, Scientific Research Labs (Dearborn, MI)
    [Original, Active Member]
  • General Motors Corporation, Polymers Department (Warren, MI)
    [Original, Active Member]

ATP Project Manager
H. Felix Wu, (301) 975-4685
felix.wu@nist.gov

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