JEC Composites Innovation Awards Ceremony 2024 - Automotive & Road Transportation - Design Part

Automotive & Road Transportation - Design Part
Finalists
Monolithic CFRP-Aluminum Monocoque:
A Novel Approach for Carbon Neutrality
Toyota Motor Corporation (Japan)

Ultra-Light CF Thermoplastic Composite Door
Center for Composite Materials – University of Delaware (USA)

1st Certified Large 350l Type IV H2 700 Bar Tank
Voith Composites SE & Co. KG (Germany)

WINNER
Monolithic CFRP-Aluminum Monocoque:
A Novel Approach for Carbon Neutrality
Toyota Motor Corporation (Japan)
tytlabs.co.jp
Partners:
• Toyota Central R&D Labs., Inc (Japan)
• Toyota Customizing & Development Co., Ltd. (Japan)
• TISM Inc. (Japan)

A full-scale variable axial CFRP-aluminum semi-monocoque was designed, fabricated, and evaluated. It showed a 15% weight reduction with minimal fiber waste (4%) and assembly cost.

This technology aims to improve carbon neutrality through the effective use of carbon fiber reinforced polymers (CFRPs).
The technology creates 3D monolithic CFRP-aluminum structures by integrating anisotropic topology optimization, Turing pattern fiber path generation, tailored fiber placement and nano uneven anodization bonding, to optimize fiber function and material utilization.
A semi-monocoque prototype demonstrates the potential for weight reduction in large 3D structures with complex topology using large fiber tow (50K) placed on 5 km of design paths with only 4% fiber waste.

Key benefits:
• Full-Lifecycle Carbon Neutrality
• Weight Reduction
• Minimized Fiber Waste and Assembly Cost
• Optimized Material Usage
• Advanced Manufacturing Process