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Ford Begins Testing Carbon Fiber Subframe from Magna

Ford Motor Co. has begun validation tests on a prototype carbon fiber composite subframe co-developed with Magna International Inc.

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Ford Motor Co. has begun validation tests on a prototype carbon fiber composite subframe co-developed with Magna International Inc.

The two companies have been working on the component for more than a year. The subframe assembly, which supports the engine and front suspension, replaces a 45-part component with one that contains just two molded and four metal parts. The supplier also says its design cuts tooling costs by at least 30%.
 

Ford is testing the system in a Fusion midsize sedan. Magna tells Automotive News that the carmaker will decide by year-end whether to put the assembly into production.

Carbon fiber is strong but also brittle compared with high-strength steel. Magna says its design can absorb only 5% of the energy involved in a front-end crash. The company acknowledges that steel and perhaps other metals would be required to meet crash standards.

Magna tells AN that side doors may be a more likely, though also challenging, next application for carbon fiber. The material is already used in rear liftgates, where crash energy absorption isn’t a big performance issue.

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