Cost and weight efficient partitioning of composite automotive structures

To make carbon fiber composites not only weight but also cost effective in high volume production the different cost drivers need to be addressed and new design philosophies considered. This study analyzes integral and differential design approaches when partitioning large complex composite structures. The influence of different partition philosophies are investigated based on a framework of composites manufacturing cost modelling and structural optimization and the effects are exemplified by a case study. The results show that depending on how the partitioning is made the structural performance and the manufacturing cost is affected. More particularly, if the partitioning is made with the most beneficial philosophy differential designs can improve both these important parameters. POLYM. COMPOS., 38:2174–2181, 2017. © 2015 Society of Plastics Engineers