TABASKO technology enhances Porsche components with lightweight carbon-fiber tapes

Porsche unveils TABASKO, a tape-based carbon-fiber process improving rigidity and lowering weight in vehicle parts using recyclable polypropylene.

Porsche has unveiled an innovative approach to automotive component design — TABASKO, which stands for Tape-Based Carbon-Fiber Lightweight Construction. Developed by Porsche Engineering, this technology introduces not just a new material but a method of enhancing existing plastics, paving the way toward lighter and more sustainable vehicle construction without compromising strength.

The core aim of TABASKO is to reduce component weight while maintaining structural integrity. As modern vehicles, especially electric ones, grow heavier due to safety features and added technology, such solutions are becoming essential. The base material is polypropylene, commonly used in car interiors. While affordable and recyclable, its mechanical properties are limited — typically improved with glass fibers (PP-GFx). TABASKO offers an alternative: the integration of 0.2 mm thick carbon-fiber tapes precisely placed where they deliver maximum effect.

Initial testing was carried out on a large part — the luggage tray of the Taycan model. The results were impressive. The TABASKO version was 15% lighter and required 66% more compressive force to reach the same deformation as the standard tray. In bending tests, the tape-reinforced samples demonstrated 2.5 to 2.8 times greater rigidity. Impact resistance also saw a fivefold improvement.

The technology was designed to integrate seamlessly into existing manufacturing lines. Engineers adapted the process to standard injection molding machines. The tapes are laid in automatically and held in place using vacuum channels, allowing for efficient scaling. To date, six patents have been filed for TABASKO, covering everything from the material structure to the production method and tooling process.

The technology has completed its prototype stage and is preparing for series production. Engineer Michael Johann compared the moment to watching a child take its first independent steps. And judging by the early results, TABASKO appears ready not only to walk but to stride confidently into the future of automotive engineering.

Source: porsche.com