SMC (Sheet Molding Compound), with its characteristics of lightweight, high strength, and corrosion resistance, has become a key material for the automotive industry's transition toward light-weighting and electrification. The following are typical application cases and performance advantages of SMC in various automotive systems:
Ⅰ. Battery System: The "Safe Lightweight Armor" for New Energy Vehicles
1. Battery Housing / Battery Pack Upper Cover
Application Models: Geely Emgrand EV450, GAC Trumpchi GE3530, Changan Eado EV, Qiantu K50, XPeng P7, BMW iX series, etc.
Performance Breakthroughs:
- Weight reduction of 15%-30%; the Qiantu K50 battery box is 15% lighter than metal
- Flame retardant rating of UL94 V-0; heat resistance from -40°C to 150°C
- IP67 protection level, waterproof and dustproof; insulation ≥800V
- Thermal runaway protection time increased to 18 minutes, meeting the latest national standards
Ⅱ. Body Structural Components: The Perfect Balance of Lightweight and Safety
1. Inner Door Panel
Performance Advantages: 40% higher specific strength compared to aluminum alloy, 30% improved energy absorption in collisions, enhanced dent resistance.
Typical Applications: Luxury brand car door inner panels replacing steel, reducing weight by 35% while improving side-impact safety.
2. Tailgate / Trunk Lid：Mercedes-Benz CL Coupe trunk lid and sport Coupe rear doors use SMC, reducing weight by 40%, with Class A surface that requires no secondary coating.
3. Fender / Mudguard
Application Models: BMW X5, Jaguar F-Pace, Ford F150, Citroën C8, etc.
Technical Highlights:BMW X5 fender uses SMC, reducing weight by 20% while solving corrosion issues of traditional metal parts.
4. Roof / Sunroof Frame
Ford Bronco detachable hardtop uses AOC Liansi Palapreg P18-03 special resin, achieving lightweight and Class A surface finish.
Ⅲ. Exterior System: Innovations in Design Freedom and Durability
1. Bumper System
Performance Breakthroughs:
- Weight reduced by 40%, impact strength doubled, while complying with pedestrian protection regulations
- Single-piece production time reduced from the traditional 2 hours to 18 minutes, with a pass rate of 98.5%
2. Front-End Module / Grille
- A certain electric vehicle’s front-end module uses an SMC-carbon fiber hybrid, reducing weight by 52% and improving assembly accuracy to 0.2mm
- Integrated design combines radiator brackets, headlamp brackets, and 12 other components into a single unit, reducing assembly costs by 40%
IV. Engine System: Dual Solutions for High Heat Resistance and Noise Reduction
1. Valve Cover
Application Brands: Cummins ISM11, Daimler Unimog 600, Peugeot J9, DAF F95, commercial vehicles, and multiple passenger car models
Core Advantages:
- Weight reduced by 25%-34%, noise reduced by 5-8dB, improving in-cabin NVH environment
- Engine oil resistant, heat resistance up to 200°C, lifespan doubled
2. Oil Pan
Technical Breakthroughs:
- Uses vinyl SMC molding, addressing corrosion and vibration noise issues of traditional metal parts.
- In a heavy-duty truck, the oil pan’s weight was reduced by 30%, while the strength at the drain plug connection was increased by 20%.
V. Chassis and Functional Components: A Model of Reliability and Integration
1. Chassis Structural Parts
Innovation Cases:
- Ford collaborated with Magna to develop an SMC front subframe, using short-cut fibers combined with non-crimp fabrics, reducing weight by 25% while increasing stiffness by 15%.
- A certain brand's chassis shield replaced 17 steel components, reducing weight by 11kg while improving chassis flatness and lowering the drag coefficient by 0.02.
2. Functional Brackets
- Engine Bay Brackets: Changan's pure electric vehicle model uses SMC engine bay brackets, reducing weight by 31.3% (about 2kg), with cost only increasing by 20 RMB, while improving vibration stability.
- Battery Brackets: The SMC battery bracket in a certain model deformed less than 0.15mm during a 300,000-cycle vibration test, ensuring the battery pack remains safe and stable under complex road conditions.
VI. Interior Systems: New Choices for Comfort and Environmental Protection
1. Instrument Panel Frame / Interior Panels
- Lightweight (weight reduction of 30%-50%), flame-retardant, no VOC emissions, meeting environmental protection requirements
- High design freedom, can be integrally molded into complex surfaces, reducing assembly time
2. Seat Frames
- A certain brand's seat frame uses SMC/BMC materials, reducing weight by 40% while improving seat structural stability.
- Integrates seatbelt mounting points and seat adjustment mechanisms, reducing part count by 25%.
Ⅶ. Future Development Trends
The application of SMC composite materials has evolved from being an "alternative material" to an "innovative material," progressing from single components to system solutions, becoming a key support for the automotive industry's transition to lightweight, electrified, and intelligent vehicles. For more detailed solutions for customized products (such as battery housings and vehicle body structures), please contact us.
