November 28, 2017
News Release

Predicting the Future of Lightweight Vehicle Composites

PNNL leads team to accelerate development of affordable carbon fiber composites

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Fiber orientation prediction in 3D complex part using the Autodesk software (Left) that was imported into the 3D ABAQUS® model.

Lower cost, lighter weight materials are needed for improved fuel efficiency. By model year 2025, U.S. regulations mandate that the average fuel economy standard meets 54.5 miles per gallon, a 60 percent improvement over the 35.5 mpg required now.

While stronger and lighter than steel, carbon fiber composites are relatively expensive. For widespread adoption to occur, new, economical composites that meet mechanical and safety requirements — such as long carbon fiber-reinforced thermoplastic resins like polypropylene and nylon — need to be developed.  Rather than building molds, molding parts, and testing new composites, computer modeling can speed the process.  Using the engineering software validated by the PNNL-lead team, manufactures will be able to "see" what the structural characteristics of proposed carbon fiber composites designs would be like before they are molded.

As part of the project, PNNL also analyzed the costs of long carbon fiber components versus standard steel and fiberglass composites. PNNL found the carbon fiber reinforced polymer composite technology studied could reduce the weight of automobile body systems by over 20 percent.

PNNL partnered on the project with:

Read more about the predictive engineering project in this PNNL highlight.

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About PNNL

Pacific Northwest National Laboratory draws on its distinguishing strengths in chemistry, Earth sciences, biology and data science to advance scientific knowledge and address challenges in energy resiliency and national security. Founded in 1965, PNNL is operated by Battelle and supported by the Office of Science of the U.S. Department of Energy. The Office of Science is the single largest supporter of basic research in the physical sciences in the United States and is working to address some of the most pressing challenges of our time. For more information, visit the DOE Office of Science website. For more information on PNNL, visit PNNL's News Center. Follow us on Twitter, Facebook, LinkedIn and Instagram.

Published: November 28, 2017