Development of the world's first carbon fiber reinforced thermoplastic (CFRTP) composites door marks a pioneering achievement in the field of automotive manufacturing and composite materials. The ultra-lightweight CFRTP door structure, developed as a lightweight alternative for the closures of the 2016 Acura MDX, is not only 45 % lighter than its equivalent baseline steel door structure, but also significantly easier to manufacture and assemble. Use of CFRTP composites allowed further structural optimization, and significant parts consolidation, reducing the number of structural parts to be manufactured and assembled by half (52 %).
the manufactured CFRTP door prototype not only met the federal crash safety standards (FMVSS 214, IIHS moving deformable barrier side impact), but also exceeded the crash performance of the baseline steel door by a notable margin. This holds substantial implications for the U.S. economy and the future of sustainable transportation through improvements in fuel efficiency and reduction in vehicle emissions. This innovative CFRTP composite door demonstrates the potential of thermoplastic composites, their strategic use, and development of progressive manufacturing techniques to ultimately open new doors for composite materials for automotive applications.

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