Vehicle Design Award

We proudly would like to introduce our vehicles Kalabia as one of the research result that
we have done in recent years. Firstly we would like to tell the meaning of Kalabia. Kalabia
Hemiscyllium freycineti, is a species of bamboo shark in the family Hemiscylliidae. It is found
in the shallow ocean around the Raja Ampat Islands in West Papua, Indonesia. The reason why
we chose this name because we want this vehicle can move freely in the streets as good as
Kalabia move in the water.
Vehicle that we take include in SEM 2014 even is Kalabia evo-4. Kalabia evo-4 is an
development of its predecessors. We did some research on various things to get the most optimal
results. Our focus research is how to make the vehicle as light as possible so that it can make
minimal fuel consumption. There are two objects to get a light vehicle that we do from year to
year they are body and frame. On this occasion we would like to describe a manufacturing
research body.
Thing to note to get a lightweight body is the material selection, material selection is very
important in determining the weight of the body. From year to year we tried to find the right
composition for a lightweight but rigid body. Here will be presented on our research for recent
years.

1. Kalabia (SEM Asia 2011)

Material of body : 2 layer fiber glass C-glass woven roving 200gr/m2 +

a layer CSM (chopped strand mat) 200gr/m2
Body manufacturing process : hand layup
Body weight : 35 kg
Surface area : 7 m2
2. Kalabia evo-2 (SEM Asia 2012)

Material of body : 2 layer fiber glass C-glass woven roving 200gr/m2 +

a lapis CSM (chopped strand mat) 200gr/m2
Body manufacturing process : hand layup
Body weight : 28 kg
Surface area : 6 m2

3. Kalabia evo-3 (SEM Asia 2013)

In this vehicle we try to combine different materials from previous years, we used a layer
fiber glass multiaxial 200gr/m2, + a layer fiberglass surface tissue 30gr/m2. With this
combination we may charge a lightweight body with a total weight of 20 kg with the same
shape as the previous generation. But the lack of this combination is that the body has a
lower stiffness.
 Material of body : a layer fiber glass multiaxial 200gr/m2, +
a layer fiberglass surface tissue 30gr/m2
Body manufacturing process : hand layup
Body weight : 20 kg
Surface area : 6 m2

4. Kalabia evo-4 (SEM Asia 2014)

In this generation we make any major changes in the body. The first is in terms of form, the
body which we make now are fully closed in order to the flow through the car properly
distributed. In addition, the body is more smooth so that the air drag force is smaller.
Besides, we also make major changes in the material. In this vehicle the material we use is a
layer of carbon fiber and is assisted by a layer core mat. Core mat has function to provide
rigidity. Method for making the body is a vacuum infusion.

Material of body : a lapis fiber carbon 240gr/m2 +

a lapis Soric 2mm
Body manufacturing process : vacuum infusion
Body weight : 15 kg
Surface area : 8 m2

From year to year we tried to reduce the weight of the body. Take a look at 2012-2013, with
same broad body shape we succeeded in reducing the body weight of about 8 kg. However
there is a shortage in the rigidity body, namely its body still has low stiffness. Therefore in
2014 we try to make the body light and rigid. We decided to use a core material such as soric
which can add to the rigidity of the body. In addition, we use a carbon fiber which has
stronger properties than glass fiber. With the composition of the material, we can reduce the
weight of about 5 kg, with a larger surface area records.
Innovation 2014: Soric
Soric is a polyester nonwoven material with a compression resistant hexagonal (XF, SF,
LRC) or random dot-printed (TF) cell structure. These pressure-resistant cells, which are
separated by channels, contain synthetic micro-spheres.
The cells do not absorb resin and therefore limit the total resin up-take. Since these cells are
pressure resistant, they create thickness in the laminate even when pressure is applied by
vacuum bag. The channels facilitate resin flow and form a pattern of cured resin with good
mechanical properties and excellent bonding to the outer skins.

Soric

Manufacturing process:

A. First mold, made of clay

B. Second mold, made of fiber glass
The surface smoothed with putty

C. Third mold, made of fiberglass

D. Vacuum process
E. Final

Note : all the manufacturing process was did by ourselves.