R&D Achievements
R&D
We engineer lightweight
innovation through continuous R&D.
Through continuous research and development, we have accumulated advanced technologies for applying new materials
and manufacturing processes, supporting the production of competitive products and customized solutions for our customers.
R&D Project Experience
Participated in joint R&D projects with leading domestic and international research institutes and companies, including Korea Institute of Industrial Technology (KITECH),
Korea Automotive Technology Institute (KATECH), Ulsan National Institute of Science and Technology (UNIST), Hyundai Motor Company, NVH Korea, and FRAUNHOFER
Developed lightweight component technologies for
automobiles, aircraft, and transportation equipment
by applying composite materials (LFI, CFRP, CNF,
etc.) and advanced processes such as FBIM and
multi-material bonding technologies
Developed lightweight technologies for automotive
interior and exterior components based on GMT and
SMC materials
Developed next-generation manufacturing
processes utilizing advanced composite materials
| No. | Project Title | Managing Authority | Participating Organizations | Period | Budget (KRW 10,000) | Remarks |
|---|---|---|---|---|---|---|
| 1 | Development of GMT Mold for Passenger Vehicle Tire Case | Korea Industrial Complex Corp | DONG-A ENG (Lead), KITECH | 2005.11~2006.06 | 6,300 | GMT |
| 2 | Development of Lightweight Platform for Electric Vehicles | Korea Industrial Complex Corp | DONG-A ENG (Lead), MPIS Korea | 2006.11~2008.02 | 9,800 | |
| 3 | Development of Integrated Cap-Side Parts for Noise Reduction in Commercial Vehicles | Jeonbuk Institute of Automotive Technology | DONG-A ENG (Lead) | 2010.11~2011.03 | 4,000 | |
| 4 | Development of SMC Mold for Oil Tank | Jeonbuk Institute of Automotive Technology | Haeyang Industry (Lead), DONG-A ENG | 2010.01~2010.11 | 25,000 | SMC |
| 5 | Development of LFI Forming Mold | Jeonbuk Institute of Automotive Technology | Haeyang Industry (Lead), DONG-A ENG | 2011.03~2011.11 | 15,000 | LFI |
| 6 | Lightweight Roof Panel Development for Large Buses Using SMC Forming & Joining Technology | Korea Industrial Complex Corp | Ultra Co. (Lead), DONG-A ENG | 2011.10~2012.05 | 10,960 | SMC |
| 7 | Development of High-Cycle RTM Forming Technology for High-Strength FRP Parts | Small & Medium Business Cooperation | Haeyang Industry (Lead), DONG-A ENG | 2011.10~2012.03 | 75,000 | RTM |
| 8 | 2013 Pilot Program for Manufacturing Robot Distribution (Robot-Based Ultrasonic Trimming System) | Ministry of Trade, Industry & Energy | DONG-A ENG (Lead), Hankuk Delchem + 3 partners | 2013.07~2014.03 | 1,093 | |
| 9 | Development of LFI Mold System for Lightweight Automotive Parts | Jeonbuk Institute of Automotive Technology | Haeyang Industry (Lead), DONG-A ENG | 2014.08~2016.01 | 7,500 | LFI |
| 10 | Development of CFRP Processing Technology | Gyeongbuk Local Government | Ilji Tech (Lead), DONG-A ENG | 2014.10~2017.03 | 5,800 | CFRP |
| 11 | Development of Fiber Blow-Injection Molding Technology for 3D Nonwoven Parts | Ministry of Trade, Industry & Energy | KITECH (Lead), DONG-A ENG + 6 partners | 2016.07~2021.06 | 731,500 | FBIM |
| 12 | Development of Big Data Platform & Automated 3D Mold Design Software | Ministry of Trade, Industry & Energy | DONG-A ENG (Lead), Geonsolution + 4 partners | 2019.10~2021.10 | 98,500 | Smart Manufacturing R&D |
| 13 | Development of Big Data Platform & Automated 3D Mold Design Software | Gyeonggi Industry-Academia Foundation | DONG-A ENG (Lead) | 2019.07~2019.08 | 8,470 | |
| 14 | Development of EV Component Manufacturing Technology Using Cellulose Nanofiber | Ministry of Trade, Industry & Energy | NVH Korea (Lead), DONG-A ENG + 4 institutes | 2021.09~2024.12 | 816,800 | CNF |
| 15 | Development of 25% Lightweight Battery Carrier Module for 350kW Hydrogen Electric Trucks | Ministry of Trade, Industry & Energy | EnHap (Lead), DONG-A ENG, KAMTIC, Kunsan Univ. | 2022.04~2023.12 | 216,212 | Hydrogen EV |
| 16 | Smart Factory Advancement Project for DONG-A ENG | Gyeonggi Techno Park | DONG-A ENG (Adopter), Gongnip Geonsolution | 2019.07~2020.01 | 200,000 | Smart Factory |
Molds for New Technology and Special Processes
| No. | Developed Mold | Objective | Material | Forming | Key Benefits |
|---|---|---|---|---|---|
| 1 | Aircraft cargo door Frame and Beam | Localization of aircraft cargo-door Frame/Beam via thermoplastic composite thermo-compression molding | Thermoplastic composite (LM PAEK CF UD Tape) | Preform thermo-compression molding | Lightweighting (30–50% vs metal) Improved process efficiency and structural safety Product developed for a domestic HY steelmaker |
| 2 | Aircraft door preform | Development of fixtures for aircraft door preform molding (ATL) | Carbon fiber prepreg | ATL layup preform molding | Lightweighting and large-area part application Product developed for a domestic D airline |
| 3 | Stabilizer Bar | Hollow structural parts using carbon-fiber prepreg bladder molding | Carbon fiber preform (braiding) + resin | Bladder and pressure thermoforming | Lightweighting via hollow structure Aircraft ducts and unmanned-mobility lightweight structures Product developed for a domestic HY automaker |
| 4 | Composite BACK FRAME | 30–50% lighter, high-stiffness seat back frame vs metal using continuous-fiber composites | Base (PA6 or PET continuous fiber), rim (PP) | Base/press molding + rim/injection molding | Maximum lightweighting Consistent quality Part integration (no bolts/adhesives) |
| 5 | Tailgate and agricultural-machine outer panels | Unpainted high-gloss exterior parts; lightweighting and surface quality for large EV, agricultural, and unmanned-vehicle exterior parts | Surface layer (thermoplastic sheet) + reinforcement (long fiber + PU) | Vacuum forming and LFI (Long Fiber Injection) | High-gloss surface quality Lightweighting and structural stiffness together Product developed for a domestic K company |
| 6 | Aluminum cooling plate (Cooling Plate) | High-efficiency liquid cooling plate for UAM/drone battery packs (thermal-runaway prevention) | Aluminum sheet (upper/lower) | Stamping + groove machining + joining | Lightweighting and thermal-management efficiency Airtightness and reliability Broader applicability |
Other Mold Development Records
| No. | Product | Application | Material | Features |
|---|---|---|---|---|
| 1 | CARRIER | Automotive parts | GMT | Injection + insert, integrated stiffness reinforcement |
| 2 | BATTERY TRAY | EV battery | SMC+STEEL | Lightweighting via fiber-reinforced material and inserts |
| 3 | Helicopter blade | Helicopter | PC impregnation | Localization; prototype mold delivered |
| 4 | Carbon material specimen | Automotive specimen | Carbon fiber | Mold for new materials (Hyundai Motor R&D) |
| 5 | UNDER COVER | Underbody protection | Azdel | Lightweighting (about 1/3 vs previous GMT) |
| 6 | High-speed RTM parts | Prototype/production | High-speed RTM (PU) | Lightweight, high-stiffness |
| 7 | BOARD COMFORT | Truck bed | PU + honeycomb | Lightweight, high-stiffness high-speed foam molding |
| 8 | Helmet | Ballistic protection | Multi-layer PC sheet | Localized mold manufacturing |
| 9 | ROOF SIDE | Bus roof side | SMC | Lightweighting via same-/dissimilar-material joining |
| 10 | INNER PANEL | Automotive parts | Glass fiber + PU | Lightweight, high-stiffness RTM process |
| 11 | BONNET | Automotive parts | Carbon Fiber + Epoxy | Lightweight, high-stiffness |
| 12 | RTM body parts | Tactical-vehicle bumper/roof panel/specimen bumper grille / Roof Inner, Out | RTM process materials | Preform and forming molds |
| 13 | HYDROGEN LINER | Hydrogen-vehicle/industrial tank liner | Rotational (thermoforming) material | Level-4 direct/indirect thermal rotational molding, one-piece process |
| 14 | ENG SIDE COVER, SIDE DOOR / blow cover (LFI) | EV and agricultural-machine exteriors | Long fiber (LFI) | Lightweighting, vacuum/foam molding, eco-friendly unpainted process |
| 15 | SEAT BACK (carbon fiber) | EV seat frame | Continuous-fiber thermoplastic (CFT) | Steel replacement; strength and lightweighting |
Key Research Project Outcomes
Project 1
Development of Fiber Blow Injection Molding (FBIM) Technology for Manufacturing 3D Nonwoven Components
FBIM is an innovative single-step process that directly opens, mixes, and forms short fibers, replacing conventional multi-stage manufacturing processes to significantly
reduce process time and production costs. The technology enables the fabrication of complex 3D geometries and precise control of fiber density and orientation, contributing
to the development of high-performance lightweight components and enhanced global competitiveness.
- Development of FBIM molding processes optimized for automotive components
- - Development of optimized molding stations and component-specific molds
- - Mold design and manufacturing for headliners, floor carpet pads, and ISO DAS pads
Participating Organizations
Korea Institute of Industrial Technology (KITECH), NVH Korea, DONG-A ENG, and others
Project 2
Development of a 25% Lightweight Battery Carrier Module for 350 kW-Class Hydrogen Electric Commercial Trucks
- This project focuses on lightweight technology development for hydrogen-powered commercial trucks
- - Achieves over 25% weight reduction compared to conventional steel structures
- - Optimized design and mold development considering SMC resin flow and forming characteristics
- - Mold development for full-scale vehicle application of battery carrier trays
- - Mold development utilizing multi-material hybrid structures (aluminum + composite materials)
Participating Organizations
Wonho, KAMTIC, DONG-A ENG, and others
Project 3
Development of Electric Vehicle Component Manufacturing Technology Using Cellulose Nanofiber (CNF)
- This project aims to develop manufacturing technologies for electric vehicle components
using eco-friendly cellulose nanofiber-reinforced composites and low-pressure injection molding processes- - Optimized mold design to ensure uniform resin filling according to product geometry within the mold
- - Optimized mold design and manufacturing for applying cellulose nanofiber (CNF) to battery upper covers
Participating Organizations
NVH Korea, Korea Automotive Technology Institute (KATECH), UNIST, FRAUNHOFER, DONG-A ENG, and others
Project 4
Development of Aircraft Cargo Door Component Forming Molds Using Thermoplastic Composite (CF UD TAPE)
- Developed forming technology for aircraft cargo-door (Frame/Beam) parts using thermoplastic composite (LM PAEK CF UD Tape)
and automated layup / thermo-compression processes- - Mold design and manufacturing optimized for AFP/ATL processes, utilizing low-viscosity characteristics
- - High-performance structural molds for aerospace, AAM, and defense that satisfy both high-load support and lightweighting
Participating Organizations
HY Steel, DONG-A ENG, and others
Project 5
Development of Stabilizer Bar Forming Molds Using Carbon-Fiber Prepreg Bladder Molding
- Developed forming molds for hollow stabilizer bars using carbon-fiber prepreg bladder molding
- - Dedicated molds covering prepreg layup → bladder connection → mold clamping and heating → internal pressurization → curing and demolding, considering the bladder-insert structure
- - Close-contact molding against the mold surface achieves a smooth appearance without post-processing; expected expansion to lightweight structures for unmanned mobility and tactical vehicles
Participating Organizations
HY Motor, Company M, DONG-A ENG, and others
Address.
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Tel.
+82 31-492-5237
Fax.
+82 31-492-5251
E-mail.
sales@dongaeng.co.kr
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