SPE Automotive Conference speaker to discuss composite car manufacturing with lower CO2 emissions than Teslas

Keynote speaker Casey Putsch will present design considerations for the manufacture of automobiles using composite materials at the 25th Annual Composites Conference and Exhibition to be held by the Society of Plastics Engineers in Novi, Michigan from September 3-5, 2025. Readers can register to attend the ACCE 2025 for $200 to $800 to learn about the latest composite materials for vehicles.

Car manufacturing and use generate significant carbon emissions. Tesla estimated the CO2 generated by its Model 3/Y vehicles is between 72 and 116 grams per mile. This does not include the CO₂ generated by its other operations, including design, testing, and sales. EVs can generate less CO₂ than internal combustion engine (ICE) vehicles, especially when comparing popular vehicles commonly purchased, such as the Tesla Model 3 versus Toyota RAV4.

However, Putsch has noted that antiquated design considerations and market forces have led to poor material choices and vehicle designs that can be significantly improved. He has prototyped the Omega two-seater using advanced composite materials which "can contribute to the mass production of stylish and affordable vehicles that are energy efficient and better for the environment with traditional internal combustion engine technology."

The Omega gets more than 100 mpg using a conventional Volkswagen turbo diesel engine, yet achieves lower energy generation emissions when driven versus the Tesla Model 3. Manufacturing and end-of-life recycling carbon emissions are also lower because the body uses lighter composite materials that are more easily recycled than fiberglass or carbon fiber.

Furthermore, the Omega does not need to carry around a ~1,000 pound battery pack like the Tesla. Smart design choices further reduce the vehicle weight, including the use of seat cushions that attach directly to the rear bulkhead.

The Omega also uses good aerodynamic design to increase fuel economy. Digital cameras replace side mirrors to see behind, the wheel covers are non-rotating, non-vented 'pizza pans' for smoother airflow, and the rear uses a Kammback design to reduce drag.

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