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5033405 innovations in body design of the new 911 infographics 2019 porsche ag
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april 11, 2019 - Porsche
The multi-material mix of the new Porsche 911
The consistently evolved composite design – which now consists of more aluminium, less steel and new composite materials – once again cuts the weight of the bodyshell by around seven percent, without making any compromises in terms of stability, rigidity and safety, which are all at least at the same exemplary level set by the predecessor model.
To achieve this, #porsche developers took a different approach by using different plastic materials to create a hybrid design in the A-pillar that guarantees a high degree of occupant protection in the event of the vehicle overturning. This innovative solution replaces the previous tube reinforcements made of super high strength steel. The greatest benefit being that the new reinforcement cuts the overall weight by 2.7 kilograms and also lowers the centre of gravity. Both effects have a direct impact on the outstanding handling dynamics of the sports car.
The composite component consists of three elements: a so-called Organo sheet, additional die-cast ribs and a structural foam. Organo sheets are pre-fabricated, highly sturdy semi-finished products made of fibre-glass reinforced plastic. These sheets are cut and reformed as part of a multi-stage process for use in the #911 Cabriolet. In the same process step, the component is equipped with a ribbed pad made of die-cast plastic. In the last process step, an additional layer of structural foam is added to the hybrid component. This layer expands when exposed to heat during the painting process to thus secure the reinforcement within the A-pillar cross-section. The A-pillar itself consists of super high strength sheet metal components such as boron steel.
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