GM using Continental Structural Plastics’ TCA Ultra Lite in Corvette for 20 lb weight savings
22 July 2015
Continental Structural Plastics (CSP), a global provider of lightweight composite solutions, announced that its Tough Class A (TCA) Ultra Lite material, introduced in September 2014, is now in production on the 2016 Chevrolet Corvette. The use of TCA Ultra Lite, a Class A body panel material, results in a 20 lb (9 kg) weight savings on the Stingray Coupe model. This is the first production use of CSP’s Ultra Lite advanced composite.
Ultra Lite technology uses treated glass bubbles to replace some of the CaCO3 (calcium carbonate) filler, allowing the resin to adhere to the matrix and increase the interfacial strength between the bubble and the resin. This is a patented treatment technology that results in a more robust resin mix that makes molded parts more resistant to handling damage, and prevents the micro-cracks that cause paint pops, pits and blistering. The treated bubbles also help with paint adhesion and bonding characteristics.
Depending on the body component being developed, design studies have shown that CSP Ultra Lite—a 1.2 specific gravity (SPg) sheet moulding compound (SMC) formulation—offers a weight savings of up to 21% over the company’s mid-density TCA Lite (1.6 SPg), and 35% over its industry-proven standard TCA material (1.9 SPg).
Through a joint continuous improvement effort, Chevrolet and CSP have significantly reduced the density of the Corvette body panels—from 1.9 specific gravity for the 2013 model year, to 1.6 specific gravity for the 2014 model year to 1.2 for the 2016 model year.
—Christopher Basela, Lead Engineer for Corvette Body Composites
On the C7, a total of 21 body panel assemblies, including doors, decklids, quarter panels and fenders, are molded from TCA Ultra Lite.
In materials engineering, shaving a single pound per car is a significant accomplishment, so saving 20 pounds per car is monumental. This is a great example of how Chevrolet is continually looking for innovations that improve performance on Corvette, and could benefit possible future applications.
—Tadge Juechter, Corvette Chief Engineer
When combined with CSP’s patented vacuum and bonding manufacturing processes, TCA Ultra Lite offers a premium Class A finish with paint and gloss qualities comparable to metals, including aluminum. The material is able to withstand the E-coat process, and passes all OEM paint tests. It also offers reduced costs at all volumes—and for production volumes under 150,000, tooling costs for composites can be as much as 50-70% less than those for stamping steel or aluminum, the company said.
For more than 40 years, Continental Structural Plastics (CSP) has provided leading-edge technologies in light-weight materials and composite components for the automotive, heavy truck, HVAC and construction industries. Headquartered in Auburn Hills, Michigan, CSP holds more than 50 patents covering materials development and manufacturing processes in composite materials formulation, engineering design and manufacturing technologies.
"WOW" a full 20 lbs weight reduction!
Posted by: HarveyD | 22 July 2015 at 08:55 AM