Recommend me a material

General Composites Discussions Composites Talk
#1

Hello. This is my first post, though I’ve been lurking around for a while :slight_smile: .

Anyway, I am a soon-to-be OEM manufacturer of kit cars and scatch-built cars. I’ve seen the work done by various scatch builders and have come ot a dilema in my own quest to produce cheap and easily replicable body parts.

Would you all recommend CF (or some hybrid or similar) or fiberglass? What are other options?

Here is the concept in it’s current incarnation (listed as IN DEVELOPMENT)…

There are lots of curves and things, but none of it is structural in the case I’m asking about. I can section the car and make foam molds for the plug, or I can have it CNC’d out of foam… I’m not sure which one I’ll do yet, but I’m after the right material now.

Things to consider for this…

  1. Price
  2. Weight
  3. Material performance
  4. Ease of application
  5. Ability to get material

My estimate is 6-10 cars a year for initial production, but looking at as many as 30 within 2-5 years.

Info about the car (everyone is curious)…

Hayabusa powered (heavily built, turbo’d)
AWD
AWS (steering)
1300-1600 pounds with driver/passenger

You can see the body weight would be a significant factor, but I’m worried about the cost and availability of CF.

Discuss :slight_smile:

ADDED INFO

http://xs301.xs.to/xs301/06223/Concept25.jpg
http://xs301.xs.to/xs301/06223/Concept24b.jpg
(additional photos to show front and side curvature)

#2

Most all Kit cars are built with a chopper gun for fast and cheap production.

What kind of price range are you planning to sell these at? This would better answer your question.

Most of the CF shortage is twill and I don’t think it is plain weave. Since it looks like you will be painting these cars, then Fiberglass can be use and if properly done, lite as CF and nearly equal in strength.

Are you going to do any crash testing of your design? :rolleyes:

#3

Selling price is looking at between 60k and 75k.

As far as testing, we are completing ANSYS testing now as well as ADAMS and a whole host of analysis through MSC software (makers of ADAMS). Three models have been put into the initial start-up budget for testing of all sorts including 2 crash tests after some track use testing is completed (figuring the best ratios on the chain/reversing box). The chassis is DOM tubing (space frame) so there will be no body panel crumple zones, though there are enclosed impact attenuators (pillows) inside the front portion of the car to provide as much energy absorbtion as possible (styrofoam blocks covered in CF).

Frame production goes into effect August 1st right now, pending the completion of the FEA and simulation software :smiley:

Body panels are under design currently (as evident by the renderings). We’ll work out the aero properties at a later date, but at the same time I’m attempting to get materials situated for the body work

#4

Your best bet would be to get many different materials and make test panels to test.

I’d also recommend maybe trying paper core material and also the use of Kevlar for better protection than CF.

The best would be CF Pre-preg and auto claved, but $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$:eek:

#5

SO what are some samples I should try out? It’s not worth my time and effort to make 25 samples and 15 of them be too flimsy or too hard to produce :slight_smile:

#6

Ya won’t know if its a waste of time until you try.