Nanocomposite body panels on the horizon

Feb. 6, 2003
A new process could make nanocomposites feasible for parts such as body panels, according to Ford Motor Co.

A new process could make nanocomposites feasible for parts such as body panels, according to Ford Motor Co. (www.ford.com). The technology uses sound waves to increase the compatibility between microscopic reinforcement materials and plastic resin used to make nanocomposite parts.

Mixing solid microscopic particles of smectite clay with plastic resin creates the so-called nanocomposites. Automotive manufacturers prefer the tiny clay particles over larger talc, mica, or glass-fiber fillers, which often leave part surfaces bumpy and cause parts to crack more easily in the cold. Nanocomposites are stronger and lighter than other plastic composites and may replace steel, aluminum, and conventional plastics in body-panel applications.

But, developing nanocomposites has been mired by the clay's lackluster interaction with automotive plastics such as polypropylene and polyethylene. Ford scientists found that bombarding clay particles with sound vibrations during mixing causes the filler to better disperse throughout the design matrix, improving a part's strength without using costly agents. "The method disperses clay particles as single platelets throughout the matrix," says Ford scientist Ellen Lee.

For example, GM's Saturn Corp. has used plastic door panels for years. But, to let the material expand and contract, larger than normal gaps are placed between doors and body side panels. Nanocomposite parts are cheaper and lighter, with better impact characteristics and lower coefficients of liner and thermal expansion. According to Lee, using nanocomposite parts will allow manufacturers to get around things like big gaps for clearances between doors. Mass production of nanocomposite parts using this technology is several years away.

Sponsored Recommendations

Sept. 16, 2025
From robotic arms to high-speed conveyors, accuracy matters. Discover how encoders transform motor control by turning motion into real-time datadelivering tighter speed control...
Sept. 16, 2025
Keep high-torque gearboxes running efficiently with external lubrication and cooling systems delivered fast. Flexible configurations, sensor-ready monitoring, and stocked options...
Sept. 16, 2025
Now assembled in the U.S., compact P2.e planetary gear units combine maximum torque, thermal efficiency, and flexible configurations for heavy-duty applicationsavailable faster...
Aug. 22, 2025
Discover how to meet growing customer demands for custom products without overextending your engineering team. Learn how scaling your automation strategy can help you win more...

Voice your opinion!

To join the conversation, and become an exclusive member of Machine Design, create an account today!