Lightweight Thermoplastic Convertible Roof Beam
The solution replaces magnesium with advanced thermoplastics and provides proof of concept for use in structural automotive applications. It uses a hybrid molding technology combining thermoforming and injection molding, enabling complex geometries for seamless integration into the vehicle while reducing component weight by 700g and cutting part count by 50%.
Why and Whom
Mercedes-Benz AG approached Röchling to develop a part that would reduce cost, weight, and component count, while setting new standards in lightweight and interior design for convertibles.
Röchling successfully met these challenges through iterative development- and design processes, combined with leading production methods and collaboration with Envalior, who co-led the CAE simulation.
Röchling successfully met these challenges through iterative development- and design processes, combined with leading production methods and collaboration with Envalior, who co-led the CAE simulation.
Partners
Mercedes-Benz AG | Bond Laminates by Envalior
Key Benefits
Traditionally, the front end of a convertible's fabric roof system includes a visible plastic trim, contrasting with the materials of the windshield frame and headliner. Removing this plastic trim creates a seamless transition between the headliner and windshield frame, offering a unique selling proposition for the Mercedes-Benz CLE Cabrio.
Awards
Award Finalist - Automotive & Road Transportation - Parts