Design, manufacturing and certification of a crashworthy all-composite door prototype for the Lamborghini Murcièlago

摘要

Development of the first all-composite door for a production high performance vehicle is discussed, including conceptual design, manufacturing, subscale testing and certification. Advanced composite materials are employed not only in the outer skin and inner panel that constitute the door, but also for the intrusion beam, virtually eliminating any metal from the structure. An innovative solution for the all-composite intrusion beam involves the use of multiple fiber materials. While carbon fibers allow for the necessary initial crushing resistance, the Kevlar fibers allow for progressive energy absorption, thereby providing improved occupant safety. The composite door replaces the original steel door with an overall weight saving of nearly 50 percent and part count reduction of nearly 70 percent per component, with a modest increase in material costs.