Automakers are under increasing pressure to improve fuel economy due to rising fuel costs and tougher emissions regulations. To meet these standards, automakers are pursuing "lightweighting" strategies to reduce vehicle weight by 30% without increasing costs. This involves using lighter materials like aluminum, carbon fiber, and plastics instead of steel. While carbon fiber offers the most weight savings, it also increases manufacturing costs. Automakers must overcome constraints like increased costs, safety concerns, and developing new infrastructure to produce lighter vehicles and meet future fuel economy mandates. Collaboration between automakers and suppliers will be key to successfully implementing lightweighting strategies.

1. The Road to
Lightweight
Vehicles

2. What is “Lightweighting” an Automobile?
• It all starts at the drawing
board . . .
• Designers and Engineers
create a CAD model
• From frame to seat covers,
all materials need to be
optimized for space and
weight

3. Why “Lightweighting”?
• Fuel prices are continuously on the rise
• Emissions restrictions in the US and Europe continue
to increase
• CAFE (Corporate Average Fuel Economy) standards,
targeted for 2025 will be the toughest ever, requiring
fuel economy averages of 54.5 mpg

4. How to “Lightweight” Automobiles
Materials
• Aluminum
• Carbon Fiber
• Plastic
• Automakers must reduce as much as 30% of an
automobiles current mass without adding
major cost

5. Material of Choice
• Carbon fibers offer differentiation
• Will be of particular interest to premium
carmakers

6. Constraints to “Lightweighting” Automobiles
• Introducing new materials can mean higher
manufacturing costs
• Concern that lighter weight vehicles will reduce
passenger safety
• New manufacturing infrastructures will need to
be intiated

7. Constraints to “Lightweighting” Automobiles
• Conventional manufacturing
methods will need to be
revisited, creating advantages
and disadvantages for material
suppliers
• Controlling cost is a major
concern

8. What’s Next?
• As new materials are
adopted, design
engineers will play a
key role in new car
designs
• Emphasis will be
placed on CAE and
CAD, including
simulation technology

9. Keys to Success
• Collaboration between suppliers and
manufacturers
• Product life cycle management solutions
reduce risk of mismatched designs
• Well-designed and implemented solutions
provide valuable insight, decrease time to
market, and reduce costs and rework

10. For More Information . . .
Download the Executive Summary at
http://www.techbriefs.com/lightweight-vehicles