Envalior and Röchling Automotive have developed a plastic frunk that also functions as a structural chassis component in a fully electric high-performance sports car. The polypropylene component uses Tepex® organosheet reinforcement with continuous glass fibers to withstand the mechanical loads generated during demanding driving conditions.
The frunk connects a strut brace to the front-axle carrier and acts as a vertical shear panel. This increases front-axle stiffness and helps maintain vehicle stability during high-speed cornering, sudden lane changes, crosswinds, and other dynamic maneuvers.
The composite reinforcement is a multilayer Tepex organosheet with 0°/90° continuous fibers in the outer layers and +45°/-45° fibers in the inner layers. The multiaxial architecture is tailored to the component's tensile, bending, and shear loads. The 0°/90° layers primarily support crash performance, while the ±45° layers contribute to torsional stiffness under lateral loads.
The frunk measures approximately 1,100 mm long, 450 mm wide, and 370 mm high. Röchling Automotive developed a hybrid molding process that combines thermoforming of the Tepex organosheet with injection molding. Both operations are completed in a single mold, producing a finished component without a separate rework step.
The process also addresses the challenges of molding a complex structural component. Röchling said achieving uniform mold filling while limiting weld lines was important for maintaining mechanical performance. The Tepex fabric layers are designed to resist fiber shifting during forming and remain intact around component corners.
Envalior said its multilayer organosheets can be manufactured with continuous fibers oriented at different angles. This allows the reinforcement architecture to follow the component's load paths. The approach also supports high-volume production of customized organosheets.
The companies see the approach as a way to integrate additional functions into future frunks while retaining their structural role. Potential features include cool boxes, drawers, cargo nets, and charging-cable holders. Envalior will showcase the application at Fakuma 2026.
Source: Envalior | News
