Hybrid composites with engineered polysaccharides for automotive lightweight

In this study, the objective was to develop hybrid composites combining the semi-crystalline engineered polysaccharide alpha-1,3-glucan (Nuvolve (TM)) with typical long glass fiber in a polypropylene matrix to optimize specific indicators of performance while also considering environmental attributes. Morphological analyses were conducted in conjunction with the evaluation of mechanical performance of these hybrid composites to gain further understanding of filler-matrix interaction. Optimum loadings of the polysaccharide / glass fiber system were identified as promising alternative to the current glass fiber / polypropylene incumbent material utilized in many commercial application (e.g. by Ford Motor Company for body interior and under-the-hood applications). Formulations with 10/15 (e.g. 10 wt.% polysaccharide and 15 wt.% glass fiber) or 10/20 showed an overall increase of >100% with respect to modulus, strength and impact properties while also demonstrating a density reduction of up to 13%. Interestingly, the life cycle analysis showed that addition of only 10 wt.% polysaccharide was able to save 4,720 liters of fuel for every ton of polysaccharide used in vehicles. Therefore, hybrid reinforced thermoplastic composites offer a balance of engineering and environmental performance to exceed materials in use. These new composites are commercially viable while also advancing the environmental stewardship and eco-efficiency within the automotive industry.

Automated summary

This study aimed to develop hybrid composites that combine semi-crystalline engineered polysaccharide with long glass fiber in a polypropylene matrix for improved performance and environmental attributes. The results showed that formulations with 10/15 or 10/20 weight ratios of polysaccharide/glass fiber exhibited significant improvements in modulus, strength, and impact properties, as well as reduced density. Additionally, the addition of only 10% polysaccharide could save a substantial amount of fuel. These hybrid composites offer a balance of engineering and environmental performance and are commercially viable.