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Automotive Lightweighting with Thermoplastic Composites: Selection & Processing Strategies

Automotive Lightweighting with Thermoplastic Composites: Selection & Processing Strategies
Language: English
Length: 90 min
Jul 15, 2025 03:00 PM
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Course Description

Prevent premature part failures and manufacturing delays when trying to achieve lightweighting, durability through thermoplastic composites in your automotive designs. Master thermoplastic composite selection, advanced processing techniques, and system-level testing, to unlock the full potential of thermoplastics for structural and semi-structural components.



This course, led by industry expert Srikanth Pilla, provides practical strategies and real-world case studies to help you:


  • Select the right thermoplastic composite based on thermal stability, chemical resistance, and mechanical performance.
  • Optimize processing techniques ( Injection molding, compression molding...) to achieve consistent fiber alignment and defect-free parts.
  • Analyze a case study of thermoplastic doors, the first of their kind in automotive composites, to see real-world application success.
Intermediate
Level
Dr. Srikanth Pilla
Dr. Srikanth Pilla
0 courses

Dr. Srikanth Pilla is a Professor and Director of the Center for Composite Materials at the
University of Delaware (UD-CCM) with faculty appointments in Mechanical Engineering,
Materials Science and Engineering and Chemical and Biomolecular Engineering. He is also the
Founding Director of ‘AIM for Composites’, a Department of Energy funded Energy Frontier
Research Center. Pilla earned his doctorate in Mechanical Engineering from the University of
Wisconsin-Milwaukee with a postdoctoral training from Stanford University. Prior to joining UDCCM, Pilla held the ExxonMobil Employees Chair in Engineering at Clemson University and was
the founding director of the Clemson Composites Center. Pilla also worked as an Assistant
Scientist at the University of Wisconsin-Madison.
Pilla’s research interests are in the fundamentals and applications of sustainable and lightweight
functional materials and manufacturing. Pilla has co-authored over 150 peer-reviewed archival
publications. His research is supported by NSF, DOE, USDA, DOD, and NASA, besides several
foundations and industries including automotive OEMs, and their suppliers.
Pilla currently serves as the Editor-in-Chief of SAE International Journal of Sustainable
Transportation, Energy, Environment and Policy. Pilla’s efforts in research and engineering
education have garnered him numerous awards, including the 2022 DOE-VTO Team Award, 2021
US EPA Presidential Green Chemistry Challenge Award, 2021 Innovision’s Sustainability Award,
2019 Composites Educator of the Year Award, 2018 SC Governor’s Young Scientist Award, 2017
Stefan Pischinger Young Industry Leadership Award, 2017 SAE Ralph R. Teetor Educational Award,
and 2016 Robert J. Hocken Outstanding Young Manufacturing Engineer award from SME. He has
supervised over 50 graduate students and postdocs, and many undergraduate students. Four of
his former team members now hold faculty positions at the University of Texas-El Paso, Cleveland
State University, Clemson University and Amasya University

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Why should you view this course?

The shift to thermoplastic composites in automotive design is driven by the need for lightweighting, recyclability, and manufacturing efficiency, especially with the rise of electric vehicles (EVs). While thermoplastics offer significant advantages over metals and thermosets—such as faster processing, impact resistance, and design flexibility—they also present key challenges. Engineers and manufacturers often struggle with material selection, processing defects like warping or delamination, and long-term durability concerns such as creep and fatigue. Without the right approach, these challenges can lead to product failures, costly redesigns, and production inefficiencies.

Join this course as a one stop solution to these challenges, through this course you will:

  1. Master material selection for optimal performance- Learn how to choose the right thermoplastic composite with an optimal strength-to-weight ratio while also effectively balancing impact resistance and cost.

  2. Optimize manufacturing techniques for consistency & quality- Get expert insights on injection molding, compression molding, and extrusion for optimal processing and fiber alignment.

  3. Prevent & fix common thermoplastic composite defects- Avoid issues like warping, delamination, voids by incorporating correct stabilizers, additives, and coupling agents.

  4. Conduct Testing and leverage digital tools for performance prediction- Gain understanding of static and dynamic testing (FMVSS, crash, and impact tests) required for OEM certification and learn to map process effects on FEA mesh to refine part design.

Who should join this course?

  • Design Engineers working with thermoplastic composites. 

  • Automotive Industry Professionals wanting to navigate the transition from metals to thermoplastics.

  • Manufacturing experts and material scientists working with thermoplastic composites for automotives.

  • Complete the course and (unlock your personalized certificate)– your badge of accomplishment awaits!

  • This course is suitable for intermediate level proficiency
    Intermediate
Course Outline

Introduction to Thermoplastic Composites

Properties and Benefits:

  1. Strength, lightweighting, and impact resistance. 
  2. Advantages over thermoset composites.

Applications in Automotive Design:

  1. Case study on automotive doors (closures). 
  2. Trends in electric vehicles (EVs) and sustainability. 

Material Selection: Matching Performance to Application

Selection Criteria: 

  1. Key properties: thermal stability, chemical resistance, and mechanical performance. 
  2. Balancing cost, weight, and performance. 
  3. Case study on material selection for automotive doors (closures).

Addressing Durability Challenges  

Failure Modes: 

  1. Fiber-matrix adhesion issues. 
  2. Environmental degradation (UV, heat, chemicals). 
  3. Mechanical fatigue and creep. 

Solutions: 

  1. Improving adhesion with coupling agents.
  2. Selecting appropriate stabilizers and additives. 
  3. Real-world examples of durability optimization. 

Creating a Digital Lifecycle to accelerate new material adoption

  1. Material Data Card Generation
  2. Concept development
  3. FEA Simulations
  4. Process Trials and Simulations
  5. Mapping Process effects on FEA mesh

Manufacturing Excellence: Best Practices for Quality

Processing Techniques: 

  1. Injection molding, compression molding, and extrusion. 
  2. Achieving consistent fiber alignment. 

Defect Avoidance: 

  1. Case study on compression molding of door with examples

Testing of Thermoplastic Composites at Systems Level 

  1. Static Testing (OEM tests)
  2. Dynamic Testing (FMVSS)

Case Study- Thermoplastic door a first for automotive composites

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30 min Q & As for this course
Interact directly with your tutor and clarify your doubts
  1. 30 mins per session for Questions and Answers
  2. Clarify your doubts.
  3. If your questions are not answered, dont worry you will recieve tutor’s reply via email after sessions.
Automotive Lightweighting with Thermoplastic Composites: Selection & Processing Strategies
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