Mixed Materials Solutions: Alternative Materials for Door Assemblies

Full Description:

The Coalition for Automotive Lightweighting Materials (CALM) has undertaken a co-development demonstration project focused on mixed-material solutions for a high volume vehicle door. The co-development, or door project, as it came to be known, maintained its own shedule, and represents the contributions of more than thirty companies. Although the efforts of the project were specifically focused on one particular door assembly, the ideas brought forward and analyzed by the CALM Co-development team are applicable to any automotive closure assembly.

By fostering communication and collaboration between and among heretofore competing suppliers the project helps to demonstrate and accelerate the introduction of lightweighting technologies. Through this collaborative process, the co-development team offers a dozen integrated solutions deploying a mix of materials and technologies. Weight reduction for a surrogate door assembly used in the project reached up to 65% compared to the initial, mild steel based design. Every technology and process included in the project is available and ready for deployment in the design of new vehicles.