CFRP Car Body Molding Future Vehicle Manufacturing Technology Combining Lightweight and Strength

Contents

Introduction

Carbon Fiber Reinforced Plastic (CFRP) is taking center stage in the automotive industry due to its exceptionally lightweight and high-strength performance. At the forefront, CFRP-based auto body structures and kits are redefining modern automotive design, delivering improved fuel efficiency, reduced environmental impact, and enhanced overall driving performance.
This column discusses the characteristics, technologies, advantages, and future prospects of CFRP-based automotives.

CFRP-based Auto Body Structures: Key Features

CFRP (Carbon Fiber Reinforced Plastics) is an advanced composite created by integrating carbon fibers into a polymer resin matrix. In automotive body structures and body kits, it enables ultra-lightweight construction paired with metal-level strength, thereby supporting highly energy-efficient vehicle design. These advantages have placed CFRP-based auto body structures and kits at the forefront of next-generation luxury, high-performance, and electric vehicles.

Lightweight Performance

CFRP rivals or exceeds aluminum and steel in strength without the weight penalty, enabling ultra-lightweight vehicle body design without compromising strength. These advantages enhance vehicle fuel efficiency, reduce emissions, and extend electric-vehicle driving range.

High Structural Strength

With superior tensile strength and excellent shock absorption, CFRP significantly enhances c[翻H2.1]rash performance, optimizing safety without compromising weight and efficiency.

Enhanced Corrosion Resistance

CFRP far exceeds metals in resistance to corrosion and environmental deterioration from humidity or salt exposure. Its resilience extends auto body life and reduces maintenance costs.

CFRP-based Auto Body Molding Technology

CFRP-based auto body structures are molded using various technologies and methods depending on the specifications and performance requirements. Each method offers distinct advantages for varying applications.

Autoclave Molding

Autoclave molding is a high-precision composite manufacturing method in which polymer resins are cured under highly-controlled pressure and thermal conditions. Carbon fibers are embedded in a resin matrix and cured within a thermo-pressurized autoclave, achieving exceptional uniformity and structural integrity (strength). In automotive and mobility industries, this method is employed for aircraft fuselages and body parts for high-end sports cars.

ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000×6,000mm / Operating temperature : at normal temperature – 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ – 0.99Mpa/cm²） / Boost pressure accuracy : 0 – 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10

Resin Transfer Molding (RTM)

RTM is a molding method where carbon fiber preforms are positioned within a closed metal mold and impregnated with resin before curing. The lower production costs, compared to autoclave molding, make RTM well-suited to automotives industries where large-volume manufacturing is paramount. RTM is also widely used for automotive exteriors and interiors because of its high precision and capacity to mold complex shapes with relative ease.

Selective Laser Sintering (SLS)

SLS is an additive molding technology that produces CFRP structures using a 3D printer. A laser is used to sinter finely powdered CFRP materials layer by layer to create three-dimensional parts. This method is particularly well-suited for prototyping and customized component production, enabling for versatile creation of products tailored to specific and individual needs.

Filament Winding

Filament winding is a technique in which carbon fiber filaments, impregnated with a resin, are wound into specified shape or geometric configurations. It is typically used for auto body parts and frames with complex designs, and is particularly effective for enhancing body strength.

Advantages of CFRP-based Auto Body Structures and Kits

Adopting CFRP-based auto body structures and kits provide several notable advantages.

Improved fuel economy through weight reduction

The use of CFRP significantly reduces the weight of the vehicle. This reduces the burden on the engine and improves fuel efficiency. Electric and hybrid vehicles also benefit from increased driving range.

Improved Fuel Economy through Weight Reduction

The significant weight advantage of CFRP reduces the engine burden and improves fuel efficiency. This is highly advantageous in electric and hybrid vehicles where weight reduction translates to extended driving ranges.

Improved Crash Safety

CFRP’s high tensile strength and shock-absorption properties effectively mitigate impact forces during a collision while reinforcing the vehicle body structure, thereby improving safety and reducing injury risk.

Enhanced Durability through Corrosion Resistance

CFRP’s superior resistance to corrosion compared to metals, enables long-term use in coastal and humid environments. Its resilience extends vehicle life and lowers the maintenance burden.

Design Versatility

CFRP’s excellent moldability enables fabrication of complex geometries beyond the limitations of conventional materials, expanding potential for functionality and aesthetic vehicle design.

Future Prospects for CFRP Car Body Molding

CFRP-based auto body structures are positioned to play a central role in addressing tightening regulations and demand for environmental- and fuel-efficient automotive solutions. Ongoing advancements in CFRP molding technology—combined with rapid progress in EV and self-driving vehicles development—are expanding potential for next-generation vehicle design and functionality.

Progress in Cost Reduction

Continuous technological innovation and the introduction of advanced production methods are expected to significantly reduce current, relatively high processing expenses. CFRP adoption is anticipated to expand across a broader range of vehicle sectors.

Material Improvements and New Technologies

CFRP material developments are expected to further enhance performance characteristics, including strength, heat resistance, and cost efficiency. At the same time, the integration of sophisticated manufacturing technologies—such as 3D printing—will likely accelerate productivity and production flexibility.

Summary

CFRP-base auto body structures and molding technologies deliver substantial performance advantages, including weight reduction, superior structural strength, and enhanced durability. With continued technological advancements and cost optimization, CFRP is expected to become an increasingly indispensable and widely adopted material for next-generation vehicles that deliver environmental efficiency combined with high performance.

ABOUT UCHIDA - 55 years since our founding

We leverage a wealth of technical expertise as a CFRP molding and processing manufacturer using FRP, GFRP, and CFRP materials. We offer a one-stop solution, encompassing design, analysis, manufacturing, secondary processing, assembly, painting, quality assurance, and testing.

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UCHIDA's equipment

We have cutting-edge equipment to ensure that we can address even the most advanced challenges of our customers.

DMG森精機 - VS1000/40/2050
X軸：2,050mm（ストローク）／ Y軸：1,000mm ／ Z軸：600mm ／テーブル作業面：2,250×1,000mm

ASHIDA MFG Co., Ltd.
Autoclave Oven 2
Size : Ø1,150x1,000mm / Operating temperature : at normal temperature - 400℃ / Design pressure : 2.0Mpa (maximum working pressure) / Vacuum system : back suction system / Vacuum units : 5

ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000x6,000mm / Operating temperature : at normal temperature - 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ - 0.99Mpa/cm²） / Boost pressure accuracy : 0 - 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10

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Oven
Size : W1,000xH1,000xD1,000mm / Temperature range : Environmental Temperature +20 - 300℃ / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 45min less / Vacuum system : back suction system / Vacuum units : 10

ESPEC CORP.
Temperature & Humidity Chamber

INSTRON
Static Universal Testing Machine 5985

Oven
Size : W7,000xH3,000xD2,000mm / Temperature range : Environmental Temperature +20 - 300℃ (Max) / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 60min less / Vacuum system : back suction system / Vacuum units : 10

NEO
X axis : 4,000mm (stroke) / Y axis : 2,000mm / Z axis : 1,200mm / C axis : 0° - ±270° / B axis : 0° - ±110° / Table working place : 4,000x2,000mm

【開発】
3Dプリンター | Markforged

Painting booth
Various painting, and clear finish is done in dedicated painting booth

Adhesion, Finishing, Coating Room
Finishing process, such as trimming, drilling, and bonding, surface treatment of the molded product type and is done in a private booth

Toshiba Matrixeye EX (Ultrasonic flaw detector)
Matrix-Arrey : 32

AMETEK CREAFORM Metra
SCAN750 Elite (3D scan)

Olympus Corp.
Inverted Microscopes

Oven
Size : W450xH450xD450mm / Temperature range : Environmental Temperature +20 - 650℃ / Temperature elevation capability : Environmental Temperature+50 - 650℃/120min less

Cutting Plotter Table working place : W1,500xL3,500mm

SHIMA SEIKI MFG., LTD
Cutting Plotter

KUKA
Robot

Krauss Maffei
Epoxy resin injection machine Resin 60L ／ Hardener 25L

Krauss Maffei
630t Press machine Height total 5,200mm ／ Length max 1,500mm ／ Width max 1,200mm ／ Whole cycle time per component part 240sec

DMG森精機 - NV5000B/40
X軸：1,020mm（ストローク）／ Y軸：510mm ／ Z軸：510mm ／テーブル作業面：1,320×600mm

Big sized clean room
JIS B 9920 cleanliness class maximum concentration (Pcs/m³） / Class 5 : 100,000m³ / Capacity : m² (16,000x16,000mm) 760m² (16,000x16,000x3,000mm) / Temperature and humidity condition : Temperature : 23℃±3℃, Humidity 65% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Temperature -5℃ during winter, Humidity 40% less