Re-engineering vehicles to reduce overall weight is becoming an increasingly important design consideration as automotive customers seek enhanced performance and fuel economy. OEMs have several options to aid in reducing overall weight. Streamlining the vehicle to include reduced component requirements can only take you so far. The bulk of a vehicle’s weight comes from vital components, many of which are traditionally manufactured using heavy steel. However, modern technology and advancements in material sciences have made huge strides in producing lightweight panels that boast the high strength and rigidity characteristics required for quality automotive manufacturing.

How Weight Affects Fuel Consumption and Performance

In the simplest of terms, the heavier an object is, the more energy it takes to effect change to the object. A heavy truck requires a larger fuel supply to start and takes longer to stop. The same truck, constructed with lightweight materials, will require drastically less fuel to get moving and provide better handling once in motion. 

The weight of the vehicle also plays a major role in how much power is required to keep the vehicle in motion. A heavier truck, for example, will require greater horsepower and thus burn more fuel, than a truck of the same size manufactured with lightweight panels. Heavy vehicles are also less agile on the road, requiring a longer distance to brake and taking curves at slower speeds. Top-heavy trucks and vans are known to tip when taking curves too quickly or too sharply. 

Swapping heavy steel components for specially designed lightweight composite panels is a highly effective way to reduce overall vehicle weight. In fact, composite panels have been used in automotive applications since the mid-1940s. Modern composite panels utilize advanced materials for even greater results.

Composite Panels for Drastic Weight Reduction

Composite panels are also widely known as sandwich panels because they consist of a core material sandwiched between skin materials. The combination of materials lends unique characteristics to the finished panel, resulting in custom lightweight solutions for a wide range of automotive components. Depending on the materials, composite panels can provide up to 50% weight reduction, while maintaining the strength and rigidity features required for durability in automotive applications.

Reducing Weight at the Core

One effective way to reduce vehicle weight is to invest in high-quality and lightweight aluminum, which is approximately a third of the density of steel. OEMs can further reduce weight by an additional 33% with aluminum honeycomb cores. These cores utilize the superior strength of the hexagonal cell structure in a way that reduces overall material requirements without compromising the strength or durability of the panel. 

While aluminum honeycomb cores offer the greatest strength-to-weight ratio, their higher price point makes them unrealistic options for all automotive components. Other cores can provide  reduced weight without the larger investment for components that don’t require as great a durability as aluminum. Paper honeycomb, for example, is a good core option for low-stress interior panels, such as ceiling and trunk panels. Low-density EPS foam is also a widely used core option due to its lightweight construction and sound-dampening capabilities.

Durability Enhancing Lightweight Panel Skins

Skin materials make up the outer layers of composite panels and play a pivotal role in overall weight and durability. For automotive applications where the goal is weight reduction, special attention should be placed on skin material to ensure optimal results. Fiber reinforced plastic (FRB) is the most popular skin material for lightweight use due to its durability and seamless application. Automotive panels with stranded polypropylene skins are another lightweight option but they do not provide a smooth, glossy finish and are typically reserved for out-of-view components. Rubber and vinyl skins for composite panels are ideal for high-traffic areas, such as floors.

Automotive Applications for Lightweight Panels

Composite panels are a versatile option for reducing overall vehicle weight and can be customized to meet the OEMs’ unique requirements. These panels are commonly used to manufacture:

  • Interior & Exterior Body Panels
  • Spoilers & Wings
  • Chassis Components
  • Dry Van Body
  • Insulated Van Body
  • Truck Cabs & Sleepers
  • Trailers
  • Doors
  • Slip in Utility Boxes

To learn more about how composite panels can help reduce vehicle weight and improve performance and fuel efficiency, or to request your consultation, please contact the experts at CPT today!