Eternal Bodywork: A Hybrid Thermoplastic-Composite and Stainless Steel Corrosion-Resistant Frame Design for Durable, Low-Maintenance Automotive Panels

This paper presents a conceptual design for automotive body panels that prioritizes long-term durability, reduced maintenance, and simplified manufacturing. The proposed ``eternal bodywork'' utilizes dual thick thermoplastic-composite inner and outer panels mechanically integrated over interlocking channels on a corrosion-resistant structural frame. A sprayed polyurea/polyurethane bed-liner coating replaces traditional paint systems, eliminating chipping, fading, and paint-defect sensitivity. The modular interlocking channel architecture is structured to enable deterministic robotic positioning, mechanical alignment, and automated fastening without reliance on post-paint surface matching or cosmetic correction. By removing paint shop infrastructure and leveraging repeatable injection molding processes, the system reduces environmental control requirements and assembly complexity while supporting scalable robotic manufacturing. The integration of structurally thick composite skins, corrosion-resistant framing, and paint-eliminating surface protection defines a dent-resistant, long-duration exterior architecture oriented toward cost-sensitive passenger vehicles as well as utility, off-road, and military platforms. This work establishes prior art for the integrated concept.