Sustainable Production Technologies of Emission-reduced Lightweight Car Concepts

The European Commission (EC) estimates in its White Paper, European Transport Policy for 2010: Time to decide, that the demand for passenger transport in the European Union (EU) will rise by 24% between 1998 and 2010, with an expansion of the car fleet by 3 million vehicles a year. This, together with the fulfilment of the EC directive on end-of-life vehicle recycling of 95% recycling rate, is a key challenge for the European transport industry if it is to enable a sustainable mobility in Europe. As 28% of the emissions of CO2 are related to transport (of which 84% are by road transport), reduction of CO2 emissions in road transport is crucial to achieve the targets agreed in the Kyoto Protocol. Weight saving is one of the most effective ways to reduce fuel consumption and thus CO2 emissions of road transport. An example for the potential environmental impact of weight saving in SLC is described in the figure below. Addressing these challenges while maintaining a vehicle's safety performance is crucial for the competitiveness of the European automotive industry, which employs over 12 million EU citizens. Only by maintaining the knowledge-intensity of automotive manufacturing at a maximum level can the EU avoid massive transfers of car production to lower wage regions in the world, so it is imperative to preserve and increase the high-quality employment. Today it is possible to construct vehicles with considerable weight reductions in expensive small/medium volume series. SLC focuses on drastically reducing the weight of mass-produced vehicle structures (e.g. Golf, Astra, Megane, Punto, etc.) and addresses specific challenges such as a low acceptance rate of risk and quality variance, short production cycle times, low manufacturing costs, short time-to-market and recyclability. SLC's main objective is to develop the integrated knowledge and technological capabilities required to design, engineer and manufacture multi-material car bodies at mass volumes (1 000/day) with a substantial weight reduction of up to 50% of body-in-white (BIW), combined with reduced raw material consumption of up to 30%. This will compare to series vehicles at manufacturing and assembly costs that do not significantly exceed those of state-of-the-art series cars of the same class (i.e. average costs of up to €5/kg weight savings).

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  • Supplemental Notes:
    • Research Institutions undertaking the sub-projects: REGIENOV (Renault Recherche Innovation acting on behalf of Renault and its subsidiaries, in particular Renault Sport and SOMAC), Commissariat à l'Energie Atomique; ESI Software, ALSTOM Transport SA, Adam Opel AG, DaimlerChrysler AG; Porsche Engineering Group GmbH, Institut für Kraftfahrwesen Aachen der RWTH Aachen, Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V., Hydro Aluminium a.s, IVM Automotive Bad Friedrichshall GmbH, Deutsches Zentrum für Luft- und Raumfahrt e.V., DIEFFENBACHER GMBH + CO. KG; LASER ZENTRUM HANNOVER E.V., Technische Universität Darmstadt, PE Europe GmbH, HEATform GmbH, Centro Ricerche Fiat S.c.p.a., Politecnico di Torino; Polytec Composites Italia s.r.l., Universita Politecnica delle Marche, University of Perugia, Comau S.p.A., ARCELOR, Sistemas y Procesos Avanzados S.L., Volvo Technology Corporation, Chalmers University of Technology, Engineering Research Nordic AB, ALCAN Airex AG, Werk Altenrhein, DOW EUROPE


  • English


  • Status: Active
  • Sponsor Organizations:

    Sustainable Surface Transport

    6th RTD Framework Programme
    European Union
    Brussels,   Belgium 
  • Project Managers:

    Goede, Martin

  • Start Date: 20050201
  • Expected Completion Date: 0
  • Actual Completion Date: 20090131
  • Source Data: RiP Project 25416

Subject/Index Terms

Filing Info

  • Accession Number: 01461639
  • Record Type: Research project
  • Source Agency: Transport Research Knowledge Centre
  • Files: RIP
  • Created Date: Jan 3 2013 1:49PM