Work

Reusable fibre composite crash boxes for sustainable and resource-efficient mobility

Year: 2025

Type: article

Abstract: In this study, a carbon fibre-reinforced polyamide 6 crash box was designed, manufactured, and crash-tested as part of a novel automotive front-end structure, developed in the EU-Project SALIENT. The crash box concept, design, and manufacturing process were based on previous investigations reported. This prior research enabled the efficient definition of key design parameters, including inner diameter ( D i {D}_{i} ), wall thickness ( t t ), trigger design, and an optimized fibre lay-up. The crash box features an innovative combination of thermoplastic composite material and an advanced manufacturing method – laser-assisted tape winding – to enable precise, automated production of reusable structures. It was tested under crushing conditions to explore further applications for the inversion mechanism, as described in the literature, to enhance crash performance and improve energy absorption. The use of a thermoplastic matrix (PA6) helped to minimize dust and particle generation, contributing to improved health and environmental safety. Additionally, the use of this material enhances recyclability, and the long service life of the composite allows for potential reuse of the structure at the End of Life in future vehicle generations.

Source: Science and Engineering of Composite Materials

DOI: 10.1515/secm-2025-0062

Authors: Patryk Nossol, Arham Saleem, Robert Meltke, Sebastian Iwan, Jorge Velasco, Marta Ingelmo

Institutions: Fraunhofer Institute for Machine Tools and Forming Technology, Foundation for Transport and Energy Research and Development

Language: English

Topic: Cellular and Composite Structures

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Industry, innovation and infrastructure, Responsible consumption and production

Open Access status: gold

Estimated APC paid: $1,187