Lotus Study Concludes Vehicle Mass Can Be Slashed 38% by 2020 for Only 3% Cost

Lotus Study Concludes Vehicle Mass Can Be Slashed 38% by 2020 for Only 3% Cost

By Scott Doggett April 27, 2010

Lotus Engineering has conducted a study to develop a commercially viable mass reduction strategy for mainstream passenger vehicles.

The study, released by the International Council on Clean Transportation, focused on the use of lightweight materials and efficient design and demonstrated substantial mass savings.

When compared with a benchmark Toyota Venza crossover utility vehicle, a 38 percent reduction in vehicle mass, excluding powertrain, can be achieved for only a 3 percent increase in component costs using engineering techniques and technologies viable for mainstream production programs by 2020.

The 2020 vehicle architecture utilizes a mix of stronger and lighter weight materials, a high degree of component integration and advanced joining and assembly methodologies.

Based on U.S. Department of Energy estimates, a total vehicle mass reduction of 33 percent - including powertrain, as demonstrated on the 2020 passenger car model -  results in a 23 percent reduction in fuel consumption.

The study highlights how automotive manufacturers can adopt the Lotus philosophy of performance through light weight.

Dr. Robert Hentschel, director of Lotus Engineering, said "lightweight architectures and efficient performance are just two of our core competencies and we are delighted to have completed this study with input from the National Highway Traffic Safety Administration and the U.S. Environmental Protection Agency to provide direction for future CO2 reductions. We believe that this approach will be commonplace in the industry for the future design of vehicles.'

The study investigated scenarios for two distinct vehicle architectures appropriate for production in 2017 and 2020. The near-term scenario is based on applying industry leading mass reducing technologies, improved materials and component integration and would be assembled using existing facilities.

The mass reduction for this nearer term vehicle, excluding powertrain, is 21 percent with an estimated cost saving of 2 percent.

A benchmark Toyota Venza was disassembled, analyzed and weighed to develop a bill of materials and understand component masses.

In developing the two low mass concepts, Lotus Engineering employed a total vehicle mass reduction strategy utilizing efficient design, component integration, materials selection, manufacturing and assembly.

All key interior and exterior dimensions and volumes were retained for both models and the vehicles were packaged to accommodate key safety and structural dimensional and quality targets. The new vehicles retain the vision, sight line, comfort and occupant package of the benchmarked Toyota Venza.

Darren Somerset, CEO of Lotus Engineering, Lotus' North American engineering division,  which led the study, said, "a highly efficient total vehicle system level architecture was achieved by developing well integrated sub-systems and components, innovative use of materials and process and the application of advanced analytical techniques."

Scott Doggett:  is an AutoObserver.com Associate Editor.