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The Fraunhofer Institute for Structural Durability and System Reliability (LBF) has developed a breakthrough in battery housing production: a cost-efficient lightweight battery housing manufactured using an in-situ CFRTP (continuous fiber-reinforced thermoplastic) sandwich process. This innovative approach produces finished lightweight battery housings in just two minutes without requiring post-processing. The housing structure consists of CFRTP cover layers with a connecting integral foam core, achieving the highest weight-specific mechanical properties while reducing material consumption by applying fiber composites only in highly stressed areas.

HP-RTM allows manufacturers to produce a complex FRP part every 2-3 minutes. This speed, combined with thermoplastic matrices (nylon or polypropylene reinforced with glass fiber), is bringing FRP to the Toyota Corolla and Ford F-150 segments. frp electromobiletech

techniques to mold complex, aerodynamic curves that would be impossible to stamp out of sheet metal. HP-RTM allows manufacturers to produce a complex FRP

is a composite material created by embedding strong fibers within a polymer matrix. This combination produces a material that is substantially stronger and stiffer than the polymer alone, while remaining much lighter than traditional metals. is a composite material created by embedding strong

The LITAPROP project at TU Dresden is investigating methods for developing novel fiber-reinforced thermoplastics (FRT) with significantly increased electrical and thermal properties for high-performance function-integrative composite structures. Using innovative intermediate products modified with nano and micro fillers such as carbon nanotubes (CNT) and cristobalite powder, researchers aim to create composites that provide structural integrity while also conducting heat and electricity—potentially allowing structural components to serve multiple electrical and thermal management functions simultaneously.

In the context of electromobility, these materials are engineered to replace steel and aluminum, offering significantly lower weight while maintaining or exceeding structural integrity and durability. 2. The Crucial Role of Lightweighting in EVs

The data is clear: the adoption of FRP in the EV market is accelerating at a remarkable pace.