Abstract: This paper describes a manufacturing process of automotive front floor made of carbon fiber reinforced plastic (CFRP). The structure of CFRP front floor was determined from the design based on metal Body-in-White. With the development of material selection, molding process and preform production, a multi-point injection rapid RTM mold has been designed and built for the purpose. A front floor made of carbon fiber reinforced thermosetting epoxy has been fabricated from the device. The sample succeeded in the stiffness, rigidity, and modal tests, combining with a significant weight reduction. The resultant product meets the manufacturer′s technical requirements, indicating that carbon-fiber-composite as the primary structural material in automotive applications is proved to be feasible.

Key words: composites, automotive front floor, RTM process