Automotive Composites Alliance Projects Growth In Use of Composites
12 April 1999
Automotive Composites Alliance Projects 27% Growth In Use of Composites Through 2003
TROY, Mich., April 12 -- The Automotive Composites Alliance
(ACA) today disclosed conservative projections for the growth of reinforced
thermoset composites used by automakers, projecting a 27% increase between
1999 and 2003 -- from 300 million lbs. (136 kg) used this model year to
380 million lbs. (172 kg) projected for 2003.
"Much of the growth will be in exterior body panel applications and in
structural and drivetrain components -- and most will replace what have
traditionally been steel components because of cost, weight and styling
advantages," says Don Kossak, ACA chairman and vice president of development
at Cambridge Industries. "This is the first year we're tallying volumes for
all thermoset reinforced composites, and we expect to see growth in all
segments."
The reinforced thermoset composites included in the industry group's
annual components list are:
* BMC (bulk molding composite)
* LCM (liquid compression molding)
* RRIM (reinforced reaction injection molding)
* RTM (resin transfer molding)
* SMC (sheet molding composite)
* SRIM (structural reaction injection molding)
Most new applications will replace traditional steel components. Why?
* Low-program cost: Composites provide design engineers with the ability
to make frequent body style changes to multiple car and truck lines at program
costs much lower than steel -- at volumes reaching 150,000.
* Weight savings: Composite components are up to 40% lighter than
competing steel applications.
* Unique styling: Composites provide automakers the opportunity to
create unique designs not available in steel.
* Parts Consolidation: Composites are used extensively for structural
components, too. Radiator supports, cowls and cross-vehicle beams made from
several steel stampings are now one- or two-piece composite assemblies.
* Technology Developments: Composites now offer many innovative
technologies -- including low-density SMC, "Lite" SMC and paint oven-
compatible RRIM -- that compete with steel and aluminum to take weight out of
car and truck components.
Some key new-for'99 composite components include:
* The decklid on the redesigned Ford Mustang, which has had an SMC hood,
spoiler and rear quarter scoops since 1994.
* The RRIM fenders on the Chevrolet Silverado -- the first ELPO-
compatible RRIM application and the first polyurea body panels processed
through an entire assembly plant.
* The cowl panels on the Toyota Sienna, a one-piece structural module
that houses the windshield wipers and attaching mechanisms.
* Low-density SMC roof inner panels on the Chevrolet Corvette that weigh
45% less than comparable steel panels. The Corvette also has RRIM fenders,
LCM structural components and an underbody made with a new automated preform
process. Among the innovations is the first use of mat-molded floor boards
with encapsulated balsa for torsional rigidity.
* The Freightliner Argosy has an RTM cab over with a complete roof cap --
one of the largest truck components in production. The aerodynamic styling
reduces drag, aiding fuel efficiency.
The Automotive Composites Alliance is an industry association comprised of
26 molders, raw materials suppliers and toolmakers that provide automakers
with reinforced thermoset composites. The ACA is a business unit of the
Composite Fabricators Association, headquartered in Arlington, VA.