UROP Project

Ultra-Light Hybrid Composite Door Design, Manufacturing and Demonstration

The objective of this proposal is to reduce full-system weight of the 2015 Chevrolet Impala front driver’s side door by a minimum of 42.5%. The approach will be demonstrated via physical testing and will consider all fit, functional, and safety requirements. A cost model will evaluate part cost of the final design and will ensure the cost target of less than $5 per pound of weight saved is met.

Task

The technical approach is evaluating material replacement and part consolidation of components in the incumbent Chevrolet Impala steel door. Our predictive engineering (PE) environment is utilized to identify robust material and process design cycles and take into account the manufacturing process limitation to seamlessly integrate them into the composite design. New material solutions will be evaluated and a small number of sub-element tests validates the approach and is used to optimize our design. Final full-scale door testing will demonstrate that our design approach leads to a composite door meeting all performance targets. Full vehicle tests will demonstrate form & fit and function of the proposed door.

Requirements

Experience with composite materials