The bio-inspired protection panel is billed as an alternative to current aluminum designs
INDIO, Calif.—A bio-inspired lightweight EV underbody protection panel will provide an alternative to current aluminum designs for protecting high-voltage battery packs from road debris, according to a release from Helicoid Industries, Inc.
Helicoid collaborated with TPI Composites Inc. (TPI) to design the EV underbody protection panel. The design uses Helicoid™ technology and is reported to leverage digital engineering, unconventional layup scenarios, biomimicry, advanced multiaxial intelligent weaving, and automated manufacturing. According to the companies, the result is a “durable, low-cost, highly engineered automotive part for the commercial and consumer automotive markets.”
The manufacturing process, developed in a manufacturing cell at TPI’s Automotive Technology Center in Warren, Rhode Island, reportedly uses “the latest in automated ply cutting and robotic pick-and-place technologies.” A multiaxial non-crimp fabric technology is employed to strategically compose the full Helicoid™ stack in sub-units. The stack layers are then robotically dosed and automatically placed and retrieved from a 2500T press, resulting in high performance precision parts, according to the release.
“We are excited to collaborate with such a strong partner as TPI on a market segment that is experiencing significant growth,” said Helicoid Industries CEO Chadwick Wasilenkoff, in a statement. “Protective crash boxes and skid plates for the growing electric vehicle market represent a significant opportunity for Helicoid. With the ability of our technology to deliver a lighter, safer, and more cost-effective solution, paired with the confidence and credibility that TPI brings to our technology, we have found a winning solution.“
The EV underbody protection panel is described as a low-cost product that is “lower in weight, higher in load bearing capability, and more resilient in impacts and crash scenarios” versus aluminum designs.
Helicoid Industries, a California-based company, has a family of patents related to the helicoid architecture for composites. The helicoid architecture is said to result in lighter, stronger, tougher, and more durable composites at a lower overall cost.
TPI Composites, headquartered in Scottsdale, Arizona, is a global company that focuses on “innovative and sustainable solutions to decarbonize and electrify the world.” The company said it delivers “high-quality, cost-effective composite solutions through long-term relationships with leading OEMs in the wind and automotive markets.”
“TPI Automotive offers full-service development and production solutions for OEM next- generation vehicles with efficient designs, superior performance, and outstanding quality,” said TPI Automotive President Jerry Lavine, in the release. “We offer industrialization expertise for engineered solutions that are quick to market, and low investment for our customers’ demanding technical and commercial battery enclosure and structural applications. We are excited to work with Helicoid to provide this innovative solution.”