Ford Global Technolgoies, LLC

Michael Cacovic

David James Bauch

Patrick James Blanchard

Jeffrey Scott Dahl

Glen Smith

A method of producing a composite article is disclosed that includes generating composite plies from a low tack composite prepreg material, connecting, by an ultrasonic welding device, two or more of the composite plies by increasing their tackiness to form a composite stack, and forming, by a compression molding device, a composite article from the composite stack.

System and process for producing a composite article

A vehicle structural or semi-structural component assembly or crash sensor assembly includes a body, wherein a first portion of the body comprises a polymer composite material and a sensor mount portion of the body is connected to the first portion; and a sensor directly attached to the sensor mount portion. The sensor mount portion comprises a polymer composite material and a flexible reinforcement material over-molded within the polymer composite material. A method for enabling tunable deceleration characteristics in a vehicle structural or semi-structural component assembly includes forming a structural or semi-structural component for a vehicle from a polymer composite material; over-molding a flexible reinforcement material within the polymer composite material at one or more locations along the component; and attaching a sensor directly to at least one of the one or more locations.

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Sterling Heights, MI, United States of America

Michael Cacovic