shape corp & gm spe award submission corvette carbon fiber ... · gm and shape partner on...
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Confidential. © Shape Corp. All Rights Reserved
Shape Corp & GM SPE Award SubmissionCorvette Carbon Fiber Bumper
Confidential. © Shape Corp. All Rights Reserved
Confidential. © Shape Corp. All Rights Reserved
2013 2014 2015 2016
Process Selection
Straight Section
Prototype
Testing & Material
Characterization
GM and Shape Partner on R&D –Target Corvette
RR Bumper
Swept Part Process
Development
Curved Pultrusion Prototypes
Swept Part Product Testing – Corvette
Spec Prod Dev.
2017
Corvette Rear Bumper Product Development History
2018 2019
FIBER RESIN COMPOSITE
Machine Design &
Dev.
Machine Delivery and Maturation in Grand Haven,
MI
LAUNCH!!
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Conventional Machine
Machine Innovations- Quality Controls for automotive- Moving die- Fast changeover- Data acquisition / archiving
First Curved Machine
Tooling Innovations- Special temperature controlled
mandrels (3D printed)- Closed Injection Box- Unique Fiber Guiding
Secondary Operation Innovations- Automated machining and assembly- Fully monitored- Mechanical fasteners and structural
adhesives
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Corvette Rear Bumper Product Development Challenges
Four layers of protection
SOLUTION
System Solution, including an innovative design for full vehicle towing. E-Coat Survival
Innovative Solutions to prevent galvanic corrosion (when joining aluminum to carbon fiber)
Optimized for Impact performance, mass, and cost
Advancements in predictive tools and optimization
WITHOUT countermeasures WITH countermeasures
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Corvette Rear Bumper Design Progression
C7 Rear AL Extruded Beam3.89 Kg
Y2 Rear Pultruded Beam1.36 Kg
Component level testing completed CAE Simulation completed Layup developed
Validation of initial properties and development of a CAE model
Preliminary laminate properties are generated using VectorLam™ CLTdesign tool
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Confidential. © Shape Corp. All Rights Reserved
Shape CorpGeneral Motors
Confidential. © Shape Corp. All Rights Reserved
STATEMENT OF CONFIDENTIALITY This document contains trade secrets and information that are proprietary and confidential to Shape Corp., and
which would provide a competitive advantage to others if disclosed. Recipients of this document must not disclose, use or duplicate its contents without prior written permission from Shape Corp.