Composite construction

From Apterawiki

The Aptera Typ-1 uses composite body panels to reduce weight and increase strength. Composite construction also makes the organic curves of its body design possible.[1]. Applying inexpensive composite manufacturing techniques to automobiles is really the greatest single innovation that enables the Typ-1.

[edit] Why use composites?

Inspired by how Cirrus Design became the second largest single-engine aircraft maker in just 2 decades by using composite materials,[2] Steve Fambro realized that these techniques could be applied to passenger cars as well. He teamed up with Chris Anthony, who had extensive experience with composites as the founder of Epic Boats LLC. They created a technique for manufacturing composites that delivers, in the words of Chris Anthony, “aerospace quality at Wal-Mart prices.”[3].

[edit] Known details

Since composite construction is their ‘secret sauce,’ as it were, Aptera Motors has been understandably tight-lipped. Steve has said the fiberglass[4][5] and epoxy[6] process creates parts with “performance characteristics as good as autoclaved parts,”[7] Parts “can be cranked out of $100,000 molds and snapped and bonded together by three people.”[8]. Videos released from the company shows single-sided molds and what appears to be fiberglass panels with a foam core and thin carbon fiber mesh reinforcement.

[edit] PAC2

Panelized Automated Composite Construction is the name given to their manufacturing technique in early literature, such as the original Aptera press release. From that:

The company's patent-pending "Panelized Automated Composite Construction", or PAC2©, lends itself to parallel assembly and has a very low initial capitalization. Additionally, AC's patent-pending hybrid technology allows off-the-shelf engines and electric motors to be seamlessly integrated for a very low cost.