Innovative Interior Design Concept Based on Composite Materials

Bertrandt and SGL, through a collaborative initiative, have developed an unprecedented integrated concept for innovative interior structures based on complex materials: "Carbon Carrier". Ready for large-scale production, the "Carbon Carrier" combines lightweight fiber composites and integrated functionality, and exemplifies the use of material mixing in the automotive industry. Carbon fiber reinforced plastics (CFRP) play a significant role in lightweight construction. Bertrandt and SGL Group combined their complementary expertise to demonstrate the potential of this material group. The objective was to develop breakthrough technology for large-scale production that offers new configuration and design options for vehicle interiors. An OEM-neutral body concept produced at Bertrandt served as the basis for developing the front interior model of an electrically powered convertible or sports vehicle. This base model incorporates all the important functions and trim components of a conventional instrument panel. Additionally, it features a newly developed design language that helps visualize the central passages and drivers' CFRP elements. Structural components were also redesigned to make the interior more open, lighter and mobile.

Michael Hage, Head of Body Development / CAE at Bertrandt, stated: "In designing the Carbon Carrier, we ensured that the components, technologies and assembly concepts used are ready for large-scale production now or in the near future. Reduced weight, especially for electric vehicles, means a broader product variety."

The greatest challenge encountered in developing the Carbon Carrier was finding the optimal configuration of matrix and fiber material, fiber length, section and orientation, layer structure and process technology that meets highly diverse requirements. The body concept is an exemplary assembled structure that showcases not only SGL Group's material and process expertise but also its experience in series component production. The optimal material mix and production technology for lightweight solutions designed for large-scale production were developed at the Lightweight and Application Center (LAC). Dr. Andreas Erber, Head of the Lightweight and Application Center at SGL Group, stated: "Throughout the entire product development process, the combined expertise of Bertrandt and SGL Group was incorporated into the Carbon Carrier – from the concept phase through design and automated large-scale production." The Carbon Carrier demonstrates a high degree of innovation and presents feasible structures for modern vehicle concepts. The expertise gained will be applied in future Bertrandt and SGL Group customer projects as well as in further collaborative initiatives. The "Carbon Carrier" exemplifies the use of material mixing in the automotive industry. Photo credit: ©SGL Group