Lightweight composite materials firm Continental Structural Plastics (CSP) has claimed that TCA Ultra Lite, currently in production for General Motors’ (GM) 2016 Chevrolet Corvette, has pared down 20lb (9kg) from the Stingray Coupe model.
TCA Ultra Lite, a Class A body panel material, a patented technology by CSP utilizes treated glass bubbles to substitute some amount of Calcium Carbonate filler to form a lighter density material.
Corvette Body Composites lead engineer Christopher Basela said: "Through a joint continuous improvement effort, Chevrolet and CSP have significantly reduced the density of the Corvette body panels - from 1.9 specific gravity for the 2013 model year, to 1.6 specific gravity for the 2014 model year to 1.2 for the 2016 model year."
In all, 21 body panel assemblies, doors, decklids, quarter panels and fenders, have been derived from TCA Ultra Lite material for the Corvette model.
Corvette chief engineer Tadge Juechter said: "In materials engineering, shaving a single pound per car is a significant accomplishment, so saving 20 pounds per car is monumental.
"This is a great example of how Chevrolet is continually looking for innovations that improve performance on Corvette, and could benefit possible future applications."
Backed by its vacuum and bonding manufacturing processes, TCA Ultra Lite claims to offer a premium Class A finish with paint and gloss qualities comparable to metals, including aluminum.
Stated to fit with E-coat process and clear all the original equipment manufacturer (OEM) paint tests, the material leads to reduction of costs at all volumes.
The company estimates that tooling cost for output of composites under 150,000 can be 50% to 70% cheaper as compared to that of stamping steel or aluminum.
CSP chairman and CEO Frank Macher said: "We have been working closely with GM to launch this patented, weight-saving technology on the iconic Corvette, achieving this conversion with no changes in material thickness or tooling while maintaining the superior surface finish required for this premium vehicle."
