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Ford carbon fibre bonnet weighs 50 percent less than a standard steel version and improves fuel economy


Ford today demonstrated a prototype carbon fibre bonnet that could help lower fuel consumption for Ford customers. The prototype bonnet weighs more than 50 percent less than a standard steel version. Carbon fibre offers a very high strength-to-weight ratio. It is up to five times as strong as steel, twice as stiff, and one-third the weight. Advanced materials such as carbon fibre are key to Ford’s plans to reduce the weight of its cars by up to 340kg by the end of the decade. The carbon fibre reinforced plastic Ford Focus bonnet displayed at the Composites Europe event in Dusseldorf, Germany is constructed from the super-strong material usually associated with bespoke racing vehicles or high-performance sports cars.


Ford has partnered with specialists from the Institute of Automotive Engineering at RWTH Aachen University, Henkel, Evonik, IKV (Institute of Plastics Processing), Composite Impulse and Toho Tenax for the course of the Hightech.NRW research project. Initial testing suggests that CFRP components such as the prototype Ford Focus bonnet will meet Ford’s high standards for stiffness, dent resistance and crash performance. The component has also performed well in pedestrian protection head-impact tests, thanks to its innovative construction of a special foam core sandwiched between two layers of CFRP.

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