Car side doors are one of the most complex parts of the body, because this component has to meet a lot of requirements. Independent of the material - steel, aluminum, magnesium, or fiber-reinforced plastics (FRP) - there are multiple important requirements.
In this paper, testing methodologies for self-supporting car side doors made from FRP are presented based on different conceptual design studies using these innovative materials. These doors and related testing methodologies have been developed in joint research and pre/advanced-development projects with different partners, car manufacturers as well as suppliers.
The importance and benefit of benchmarks, advanced experimental material analysis, substructure and full-size component testing in the product development process is discussed. Furthermore important links to the CAE-process are referred and the significant value on the whole development process is demonstrated.
Test data for new composites car side doors based on different conceptual design are presented and methodologies for further improvement of the development process suggested.