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Shape Corp & GM SPE Award SubmissionCorvette Carbon Fiber Bumper

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2013 2014 2015 2016

Process Selection

Straight Section

Prototype

Testing & Material

Characterization

GM and Shape Partner on R&D –Target Corvette

RR Bumper

Swept Part Process

Development

Curved Pultrusion Prototypes

Swept Part Product Testing – Corvette

Spec Prod Dev.

2017

Corvette Rear Bumper Product Development History

2018 2019

FIBER RESIN COMPOSITE

Machine Design &

Dev.

Machine Delivery and Maturation in Grand Haven,

MI

LAUNCH!!

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Conventional Machine

Machine Innovations- Quality Controls for automotive- Moving die- Fast changeover- Data acquisition / archiving

First Curved Machine

Tooling Innovations- Special temperature controlled

mandrels (3D printed)- Closed Injection Box- Unique Fiber Guiding

Secondary Operation Innovations- Automated machining and assembly- Fully monitored- Mechanical fasteners and structural

adhesives

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Corvette Rear Bumper Product Development Challenges

Four layers of protection

SOLUTION

System Solution, including an innovative design for full vehicle towing. E-Coat Survival

Innovative Solutions to prevent galvanic corrosion (when joining aluminum to carbon fiber)

Optimized for Impact performance, mass, and cost

Advancements in predictive tools and optimization

WITHOUT countermeasures WITH countermeasures

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Corvette Rear Bumper Design Progression

C7 Rear AL Extruded Beam3.89 Kg

Y2 Rear Pultruded Beam1.36 Kg

Component level testing completed CAE Simulation completed Layup developed

Validation of initial properties and development of a CAE model

Preliminary laminate properties are generated using VectorLam™ CLTdesign tool

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Shape CorpGeneral Motors

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STATEMENT OF CONFIDENTIALITY This document contains trade secrets and information that are proprietary and confidential to Shape Corp., and

which would provide a competitive advantage to others if disclosed. Recipients of this document must not disclose, use or duplicate its contents without prior written permission from Shape Corp.