SuperTruck 2 demonstrator. Source | Kenworth

TPI Composites Inc. (Scottsdale, Ariz., U.S.) has announced its contributions to the development, engineering and manufacturing of the all-composite cab for the Kenworth SuperTruck 2 demonstrator. TPI’s composites expertise enabled development of critical components and cab structures with significant weight reduction and improved freight efficiency.

The truck was developed over a 6-year period as part of a collaboration with the Department of Energy’s (DOE) SuperTruck program, designed to challenge truck makers to improve freight efficiency using a diesel engine as the main power source. The project was the result of a joint investment by the DOE and PACCAR, Kenworth’s parent company.

“The goal was a 100% freight efficiency improvement over our 2009 Kenworth T660, which at the time was arguably the most fuel-efficient truck in the industry. We surpassed the performance of that model to improve efficiency by up to 136%,” says Jim Walenczak, general manager of Kenworth and PACCAR vice president. “This was realized through a combination of improving fuel efficiency up to 12.8 miles per gallon while reducing our combination weight by more than 7,000 pounds.”

The ultramodern style of the Kenworth all-composite cab is 20% lighter than a comparable traditional metallic cab typical of Class 8 vehicles while also providing improvements in aerodynamics. The project was led by PACCAR, which designs, manufactures and provides customer support of premium light-, medium- and heavy-duty trucks under the Kenworth, Peterbilt and DAF nameplates. 

Composites can be molded into complex shapes, creating design flexibilities that allow for more aerodynamic designs using fewer parts. They are lighter weight, contributing to improved fuel efficiency for internal combustion vehicles and extended range on electric vehicles.

“We are thrilled to partner with Kenworth on this state-of-the-art program,” says Todd Altman, senior director of automotive at TPI Composites. “Our structural composite solutions are ideally suited for the demands of the trucking industry, offering many advantages including reduced investment and quicker to market, while also enabling the design of more aerodynamic and fuel-efficient vehicles.”

For related content, read “TPI Composites manufactures structural composites for International SuperTruck II.”