Safety, Weight Loss, and Energy Savings All Achieved! Multi-Dimensional Innovation of Fiber-Reinforced Plastics

Plastic is not only lightweight and easy to mold, but it can also enhance safety. This viewpoint has been confirmed by the Plastics is Fantastic Association.

Carbon fiber and glass fiber reinforced plastics (CFRP/GFRP) are more efficient at absorbing impact energy than steel or aluminum. Their core advantage lies in the fact that these materials fracture in a controlled manner rather than deforming.

The final result is very remarkable: while significantly reducing weight, it offers better collision protection, marking an important step forward in lightweight design.

The performance of fiber-reinforced plastics has been proven in motorsports and is now not only widely used in lightweight manufacturing but is also gradually being applied to high-volume production parts with extremely high safety requirements, such as crash boxes, B-pillars, and battery housings.

"Lightweight manufacturing is a key strategy in component production for saving materials and energy," said Professor Markus Milwich, head of the Polymer and Fiber Composite Competence Center at the German Institutes of Textile and Fiber Research (DITF) and representative of the Baden-Württemberg Lightweight Alliance. The market is experiencing rapid growth: a study commissioned by the German Federal Ministry for Economic Affairs and Energy shows that between 2001 and 2021, the number of patent applications in the field of lightweight manufacturing for plastics and plastic composites increased by nearly 400%.

Professor Milwich pointed out that "in 2019, lightweight manufacturing contributed approximately 4% to Germany's gross domestic product (GDP) and created around 3.2 million jobs."

High impact resistance

In the transportation industry, carbon fiber reinforced plastic (CFRP) is a focal point, especially in the field of safety protection. According to relevant associations, the specific impact energy absorption capacity of CFRP components can reach 100 kJ/kg, which is significantly higher than the 20-30 kJ/kg level of steel. This composite material does not fracture suddenly; instead, it disperses collision energy in a controlled, gradual manner. The hybrid sandwich structure, with plastic as the core layer and fiber-reinforced material as the surface layer, can provide significant safety protection for vehicle occupants.

Lower impact

CFRP is up to 50% lighter than steel. The weight reduction means that less energy is generated during a collision, thereby reducing the risk of injury to occupants. The Fraunhofer Institute for Structural Durability and System Reliability (LBF) has developed a 3D sandwich battery housing made of fiber-reinforced plastic, which is 40% lighter than aluminum alloy housings. This design integrates fire protection features and complies with ISO 12405-2/-3 safety standards, providing robust protection for electric vehicles with a lighter weight.

Higher sustainability

Weight reduction also means lower energy consumption. Professor Milwich explained, "Especially for mobile carriers such as cars, airplanes, and ships, reducing the weight by one gram during their lifespan can reduce fuel consumption." According to data from the U.S. Department of Energy, for every 10% reduction in vehicle weight, energy consumption can be reduced by up to 8%.

Fiber-reinforced plastics enhance efficiency without sacrificing safety. The thermoplastic matrix system based on PET (polyethylene terephthalate) has taken a crucial step forward—it not only possesses the strength of carbon fiber but also achieves recyclability.

Plastics are gradually becoming an indispensable material in high-performance lightweight structures in future transportation systems. Professor Milwich concluded: "With excellent energy and resource efficiency, lightweight design is key to achieving climate protection, sustainable development, and raw material conservation."