Glass-Fiber-Reinforced Epoxy Composite Leaf Spring for Light Vehicles: FEA, Prototype Fabrication and Experimental Validation

The demand for lighter, more fuel-efficient, and eco-friendly vehicles is increasing. Because of this, many car parts made of steel are now being replaced with advanced composite materials. One such part is the composite leaf spring, which is becoming popular because it is strong, lightweight, resists rust and lasts longer. This study focuses on designing and testing a glass-fiber-reinforced epoxy composite leaf spring for light vehicles. The process includes reviewing past research, creating a detailed 3D model, running simulations using Finite Element Analysis (FEA), making a real prototype, and testing it in the lab. The FEA examines how the leaf spring handles stress, how much it bends, and its natural vibration frequency. The prototype was made using the hand lay-up method and tested to compare real results with the simulation. The results show that the composite leaf spring reduces the overall weight by 62.16% compared to a steel leaf spring (at half-scale), while still providing equal or better strength and stiffness.