BALANCE LIGHTWEIGHT MATERIALS AND ENGINEERING TO RETAIN PERFORMANCE?

M A R C H 2 0 2 2
Lightweight
Solutions for Crash
Energy
Management
A U T O M O T I V E L I G H T W E I G H T
M A T E R I A L S U S A

STRICTLY CONFIDENTIAL
©2022 TESSERACT STRUCTURAL INNOVATIONS INC.
• Patented light-weight technology
• High specific energy absorption
• Passive structural safety for
– Vehicle occupants
– EV battery packs and
– Other sensitive components
LIGHTWEIGHTING FOR
PERFORMANCE & SAFETY
PAGE 2

• Lightweight metal composite
• Easily integrated designs
• Can absorb >50% of crash energy
TESSERACT UDU = “SKIN” & FOAM
UNIFORM DECELERATION UNIT (UDU)
PAGE 3
• “Skin” structural
components
• Stabilized
aluminum foam
• Tuned for energy
target levels

©2022 TESSERACT STRUCTURAL INNOVATIONS INC. PAGE 4
Key components:
Skin structure
Foam materials
Skin + Foam = UDU
Concept #2
Maintain load
near target
Concept #1
Bring load up to
target
Concept #3
Slow down the
crash

©2022 TESSERACT STRUCTURAL INNOVATIONS INC. PAGE 5
Skin structure combined with
composite Cymat SmartMetal™
aluminum foam installed
Fully assembled UDU
test segments
skin structure
with foam

UDU CRUSH DATA VALIDATION
PAGE 6
0
50000
100000
150000
200000
250000
300000
0 1 2 3 4 5 6 7 8
Load
(lb)
Displacement (in)
4-Layer UDU Crush Test (F-D Curve)
1
2
3
4
• 6.5 LB assembly
• Total crush
distance 7.2”
• 49 kJ energy
absorption at less
than 110,000 lb
• 69 kJ total
energy absorption
#2 Maintain
load near target
#1 Bring load
up to target
#3 Slow down
the crash

MAJOR APPLICATION AREAS:
• Lightweighting
• Crash Safety
• ICE to EV Platform Conversion
• EV Battery Protection
Structures
• New EV Vehicle Structures
• New Crash Energy Management
Structures
Applications in automotive,
trucks, aircraft, defense,
containers
KEY TESSERACT UDU TAKEAWAYS
PAGE 7
LIGHT-WEIGHT STRUCTURE
WITH HIGH SPECIFIC
ENERGY ABSORPTION
CAPABILITY
VERY HIGH ENERGY
ABSORPTION PER UNIT OF
ADDED WEIGHT

OEM TARGET PROBLEM – OVERLAP CRASHES
PAGE 8
• Current strategies have
limited effectiveness
• Not always feasible to just
add more steel, but
Limiting mass additions is
critical
• Over-stiffening specific
areas can result in
downstream problems
17% of crashes,
25%-34% of crash deaths

FULL VEHICLE UDU CRASH SIMULATION
PAGE 9
• 2014 Chevy Silverado
Public Domain NHTSA
Crash Model
• 20%-22% target - 25%
increase in kinetic
energy absorption over
baseline
• Many optimization
paths
Time = 0.10 secs
Time = 0.00 secs
0
20000
40000
60000
80000
100000
120000
140000
160000
0.020 0.030 0.040 0.050 0.060 0.070 0.080 0.090 0.100
Barrier
Contact
Force
(lbf)
Time From Start of Crash (s)
Chevy Silverado SOL Barrier Contact Force
Baseline Model With Tesseract S.O.L. UDU
1. Load raised near average 120,000 lbf
2. Load sustained at more constant value
3. Slowed the crash reducing force spikes
0
5
10
15
20
25
30
0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10
%
Increase
in
KE
Absorption
Crash EventTime (s)
Increased Kinetic Energy Absorption With
UDU vs. Baseline
% Difference of Kinetic Energy

MAJOR THEME –
ICE TO EV PLATFORM CONVERSION
PAGE 10
Meet or exceed previous testing
results with:
• increased platform weight due
to EV platform conversion
• redistribution of mass and crash
characteristics

Solutions:
1. Various beams
2. Crash boxes
LIGHTWEIGHTING: ICE TO EV CONVERSION
PAGE 11
#1 Bring load up to target
#2 Maintain load near target
#3 Slow down the crash

Situation:
• Existing ICE
platform conversion
to EV
• Battery mounted
under passengers
• Battery protected
by door beam and
side sill
Complications:
• Current battery weight and placement
• Changing a major crash energy path
• Maximize battery range
• Battery limited by crash
test requirements
• Overall weight and cost
LIGHTWEIGHTING PROBLEM –
EV BATTERY PROTECTION
PAGE 12
Side Pole Crash Test

Solutions:
• Side sill beam
• Frame tip mounted
crash box
PAGE 13
#1* Bring load up to target
#2 Maintain load near target
#3 Slow down the crash

Grab and Distribute
force over a larger area
onto the second layer
Raise and Hold 1 force near
maximum allowable level
Raise and Hold 2 force near
maximum allowable level
Reaction Beam to support
layers 1,2 and 3 to minimize
deflection
Side Sill Beam UDU shown in left hand side vehicle position
Side Sill Crash
Force Direction

• The total energy
absorbed by the side sill
beam UDU structure is
increased by the pole
embedment as shown
by the area under the
pole F-D curve. The
embedment effectively
increases the crush
distance for the UDU.
• Pole embedment into
the UDU at the outset
of the crash, and
subsequently during the
crash, generates bonus
energy absorption.

Solutions:
• Bumper beam
• Frame tip mounted
crash box
LIGHTWEIGHTING : ICE TO EV CONVERSION
PAGE 16
#1 Bring load up
to target
#2 Maintain load
near target
#3 Slow down
the crash
Frame Tip UDU:
• Bumper to frame tip
• Improves crash performance
• Example weighs 4.9 pounds
• Absorbs 48 kJ of crash
energy

OEM Application
Requirements:
• Lightweight
existing parts
• Focus on crash
relevance
Crash Box UDU:
• Fits in same volume to same mounting points
• Meets or exceeds crash requirements
• Reduced weight from 5.1 kg to 3.2 kg
• Manufacturing design & process complete
• Cost competitive with current part
REDUCE WEIGHT AT SAME PERFORMANCE
PAGE 17

REDUCE WEIGHT AT SAME PERFORMANCE
• OEM crash box
absorbed 7.8 kJ
• UDU crash box
absorbed 16 kJ
• UDU absorbed
greater than 2X
more energy

AUTOMOTIVE APPLICATIONS FOR UDU
TECHNOLOGY
PAGE 19
• Door Beams
• Firewall Panel
Crash Pads
• Fender/Whee
l Well Crash
Box
• Bumper Crash
Box
• Bumper
Beam
• Wheel Well
Crash Pads
• Pillar Beams
• EV Battery
Enclosure
System
• Side Sill Beam
• Wheel Well Crash Pads

EV APPLICATIONS FOR UDU TECHNOLOGY
PAGE 20
• Bumper
Beam
• Bumper
Crash Box
• Bumper
Beam
• Bumper Crash
Box
• EV Battery Protection
Side Sill Beam
• Battery Enclosure
Mount Crash Box • EV Battery
Enclosure Floor/Tray
Crash Pad
• EV Battery Enclosure Frame
Beam Combination

SOME UDU APPLICATIONS IN HEAVY TRUCKS
PAGE 21
• Bumper
Beam
• Frame Rail
Tip Crash
Box
• Underrun
System
(multiple
parts)
• Frame Rail
Tips Crash
Box
• Bumper
Beam
• Rear
Underrun
System
• Side
Underrun
System
• Crash Pads (Various
applications)

TESSERACT PARTNERS
PAGE 22
at at
Cymat Technologies Ltd.
SmartMetal™ aluminum foam

Multiple patents filed, pending and issued
including US and international applications - four patents issued in 2020-2021
Multiple product opportunities
with 25+ potential vehicle components covered by IP filings
INTELLECTUAL PROPERTY
PAGE 23

BUSINESS MODEL & PRODUCTS
PAGE 24
Bumper Crash Box UDU
Vertical Profile Fender
Crash Box UDU
Horizontal Profile Fender
Crash Box UDU Specialty Crash Box UDU
1.Parts Supplier
2.Technology Licensing
UDU Crash Boxes,
Beams & Pads
Side Sill
Battery
Beam UDU
Crash Box UDU
Firewall Crash Pad UDU
Crash Pad
UDUs
Bumper Crash
Box UDU

• Patented light-weight technology
• High specific energy absorption
• Passive structural safety for
– Vehicle occupants
– EV battery packs and
– Other sensitive components
UDU TAKEAWAYS FOR LIGHTWEIGHTING
PAGE 25
Applications in
automotive,
trucks, aircraft,
military,
containers

James Y. Lancaster, CEO
james@tesseractinnovations.com
+1 (979) 595-8505
W W W. T E S S E R A C T I N N O VAT I O N S . C O M

BALANCE LIGHTWEIGHT MATERIALS AND ENGINEERING TO RETAIN PERFORMANCE?

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