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Mainstream carbon fiber still 10 years off

Mainstream carbon fiber still 10 years off

Ralph Hanson January 21st, 2008 Ralph Hanson By Ralph Hanson Author January 21st, 2008
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December 31st, 1969 Most performance enthusiasts are well versed in the benefits of carbon-fiber, but if GM has its way your mom could be extolling the virtues of the space age material as well. In fact, as GM exec Tom Wallace pointed out in a recent interview, "carbon is one-fifth the weight of a composite, which is half the weight of steel." Wallace is currently in charge of GM’s sports car line, which includes cars like the Chevrolet Corvette, Cadillac XLR, Pontiac Solstice, Saturn Sky and Opel/Vauxhall GT, and he’s also part of a team investigating how high-volume, mainstream models can benefit from carbon in the same way that the Corvette ZR1 does. The key reason to use more carbon is to reduce the weight of a car and thus reduce its fuel consumption, something all carmakers will have to consider in light of toughening fuel economy and emissions standards. The ZR1's carbon fiber parts include the roof, hood, front spoiler, front fenders, side rocker panels and rear spoiler and saves about 35 pounds over the weight of the standard Corvette. This same weight saving could be achieved in other vehicles but there’s one major problem. One of the main reasons carmakers don’t slap carbon pieces onto all of their cars is because of the high cost and complexity of manufacturing it. But like any new technology there’s always a declining cost curve associated with it. “Although carbon fiber is expensive today, so was aluminum in the beginning, so was magnesium in the beginning," Wallace explained to Automotive News. Carbon-fiber is currently in high demand and is relatively scarce compared to other materials such as steel and aluminum. It doesn't help that aircraft manufacturers such as Boeing and Airbus are manufacturing their next-generation planes using composite materials and driving prices higher than ever before. The good news is that more companies are starting producing of the material and prices should come down soon. GM is not the only carmaker determined to use more carbon. Toyota has just announced a joint venture with a carbon fiber company, and other carmakers are expected to follow suit. According to Wallace it will take ten years alone to know the feasibility of carbon fiber, so don’t expect next year’s Chevy Malibu or Impala to be draped in the advanced material.
Mainstream carbon fiber still 10 years off

Mainstream carbon fiber still 10 years off

Enlarge Photo

Most performance enthusiasts are well versed in the benefits of carbon-fiber, but if GM has its way your mom could be extolling the virtues of the space age material as well. In fact, as GM exec Tom Wallace pointed out in a recent interview, "carbon is one-fifth the weight of a composite, which is half the weight of steel." Wallace is currently in charge of GM’s sports car line, which includes cars like the Chevrolet Corvette, Cadillac XLR, Pontiac Solstice, Saturn Sky and Opel/Vauxhall GT, and he’s also part of a team investigating how high-volume, mainstream models can benefit from carbon in the same way that the Corvette ZR1 does.

The key reason to use more carbon is to reduce the weight of a car and thus reduce its fuel consumption, something all carmakers will have to consider in light of toughening fuel economy and emissions standards. The ZR1's carbon fiber parts include the roof, hood, front spoiler, front fenders, side rocker panels and rear spoiler and saves about 35 pounds over the weight of the standard Corvette. This same weight saving could be achieved in other vehicles but there’s one major problem.

One of the main reasons carmakers don’t slap carbon pieces onto all of their cars is because of the high cost and complexity of manufacturing it. But like any new technology there’s always a declining cost curve associated with it. “Although carbon fiber is expensive today, so was aluminum in the beginning, so was magnesium in the beginning," Wallace explained to Automotive News. Carbon-fiber is currently in high demand and is relatively scarce compared to other materials such as steel and aluminum. It doesn't help that aircraft manufacturers such as Boeing and Airbus are manufacturing their next-generation planes using composite materials and driving prices higher than ever before. The good news is that more companies are starting producing of the material and prices should come down soon.

GM is not the only carmaker determined to use more carbon. Toyota has just announced a joint venture with a carbon fiber company, and other carmakers are expected to follow suit. According to Wallace it will take ten years alone to know the feasibility of carbon fiber, so don’t expect next year’s Chevy Malibu or Impala to be draped in the advanced material.

Tags: General Motors, Technical

Posted in: News


Comments (5 total)

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  1. By chris #1, Posted: 1/21/2008

    I think where we stand to see a lot of carbon fiber construction is in forming lighter passenger cabins that are still safe enough to not crumple. cars have gotten much heavier in the past 20 years and safety standards are just about the only reason for it. yes, engines have become "larger" (in displacement) and more powerful, but they have also become lighter. sheet steel has become thinner.

    mechanical complexity has gone up and safety standards have become tougher. these two items add weight to the vehicle, and its safe to say that carbon fiber passenger cabins will make the cars 20 years out lighter than the cars from 20 years ago and stronger and safer than the cars today.

    I wonder how malleable carbon fiber can be made. could it be used for the entire unibody?

  2. By admin #2, Posted: 1/21/2008

    Chris - yes. Carbon fibre can be made in to almost any shape. The most expensive cars have their whole monocoque made of CF. When I visited the Pagani factory I saw one being baked in their large ovens. Amazing stuff.

  3. By SuperSkyline89 #3, Posted: 1/21/2008

    Man I wish I had your job ! ! !

  4. By ohmy #4, Posted: 1/21/2008

    yea chris, as a cyclist, the industry is head of the curve in terms of using CF in their bikes. As with metals, there are different types of "type" of CF, i wont get technical, but depending on their applications, one "type" of CF is better for unilateral stiffness/absorption of vibration etc while an another type is better for more torque applications (in the bike sense, drivetrain).

    Also, the resin used in CF can be changed as well. I think Easton has added a new resin that makes for an even stronger bond (old news).

    CF is great but because of its multiple uses, as the article said, is very scarce and expensive.

    Oh, and one other thing, the weave on carbon is mostly cosmetic, there are sum performance benefits but very slightly, so if anyone ever tells you CF looks like that, they are wrong. it annoys me when I come across people and i try to educate them. thats an personal aside.

    so in terms of using CG, it really is still in its infancy in terms of different CFs/resins so teh future is bright, now only if we can make enough of the stuff!!!

  5. By Alan #5, Posted: 1/22/2008

    One thing though, how about recycling? With steel and aluminum body, some components can be recycled, but CF can't be recycled can it?

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