A Light-Weight Bumper System Utilizing Azdel® Glass Fiber Reinforced Thermoplastic Laminate

Automotive design efforts to resolve the conflict imposed by Federal regulations governing Corporate Average Fuel Economy (CAFE) and the inherent weight penalty of FMVSS-215 Bumper Standards have centered around lightweight material substitutions, most notably HSLA steels and aluminum. Recent developments in non-metallic structures are directed at further reduction in the weight penalties of steel and the cost penalties of aluminum. This study presents the investigation of a continuous glass fiber reinforced thermoplastic in a light-weight, energy-absorbing bumper system through its design, fabrication and successful prototype testing. Material properties, design parameters, molding process and vehicle impact testing will be reviewed.