Case Study: Plexus Bonds Key Components of Aluminum–Intensive Roadster

A new type of sports car, the Panoz AIV Roadster is 70% aluminum and has a curb weight of 2600 pounds. Hand built by Panoz Auto Development Company, the roadster is the first Aluminum intensive Vehicle (AIV) manufactured in the United States. Only 200 are built each year.

The vehicle’s engine and drivetrain are produced by Ford Motor Company. The Panoz’s 4.6 liter, 32-valve, V-8 powerplant rockets the car from 0-60 in a heart-stopping 4.5 seconds.

Plexus Methacrylate Adhesives are used in key structural bonding applications throughout the car. Joel Grewett, General Manager of Panoz, points out that aluminum body panels are bonded to the
all-aluminum chassis using super-tough Plexus A0420 Adhesive. Hood, deck, and door liners are also bonded in clamshell fashion using Plexus Adhesives.

Panoz’s decision to use Plexus Adhesives was heavily influenced by Ford’s own success with the product. In fact, Ford has bonded more than 5 million thermoplastic bumpers over the past decade using the adhesives with no problems.

Plexus Adhesives offer the unique combination of tensile strength and modulus of elasticity needed to produce tough, permanent bonds on a wide range of dissimilar materials.

Panoz notes that other benefits of the adhesives include minimal surface preparation, superior strength bonds compared with other adhesives, and proven durability in automotive body assembly.

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