Lightweight Body Material Solutions for the Automotive Industry Gavin Smith China International Symposium on Automotive Lightening Technology 16th 18th Sept 2015, Chongqing Agenda Global Drivers to Increased Vehicle Mass Weight Reduction Strategies Material Selection Process Selection Magna Product Development History Magna Lightweight Concepts 2 G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology Agenda Global Drivers to Increased Vehicle Mass Weight Reduction Strategies Material Selection Process Selection Magna Product Development History Magna Lightweight Concepts 3 G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology Our Drivers of New Technologies The Global Megatrends GLOBALIZATION DIGITAL LIFESTYLE RAW MATERIALS IMPACT ON ENVIRONMENT DEMOGRAPHIC CHANGE LIMITED FOSSIL FUELS URBANIZATION / MEGACITIES INDIVIDUALISM NEW MOBILITY CONCEPTS Global Megatrends with regional differences impact the automotive industry 4 G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology Magnas Innovation Pillars 5 CLEANER Efficiency and Sustainability LIGHTER Lightweight Material and Science SAFER Active and Passive Safety SMARTER Comfort, Convenience and Connectivity for future HMI demand, interior concepts will be completely changed lots of different legislation targets lead to different approaches Advanced Driver Assistance Systems (ADAS) enable semi autonomous driving improve driving performance, CO2 & fuel economy, Total Cost of Ownership (TCO) AFFORDABLE Development and Manufacturing Efficiency G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology Where is all the Weight Coming From? Vehicle weight has significantly increased over time Key Drivers Comfort/ Convenience Mandatory Safety features Fuel Economy Legislation in North America is reversing the trend, while Environmental Legislation in EU is having some impact Weight Development of a Medium Class Vehicle Example 1000 kg Source: BMW G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology 6 Drivers to Overcome Weight Issues. The automotive industry now faces the huge task of adding safety while improving Fuel economy and Reducing emissions. The only solution is to put the vehicle development programs on a strict diet. Lighter weight, stronger materials, innovative design and production methods. Cross departmental thinking for innovative solutions that benefit the complete finalized vehicle, and therefore the customer. o Safer o Cost effective o Entertaining o Quality China International Symposium on Automotive Lightening Technology G. Smith, Magna Steyr 7 Global Trends The recent trend for improved safety has had the following effect. Added many passive safety components and continues to do so. Added steel mass ( thicker or additional parts ) to improve passenger compartment robustness Pedestrian safety has a larger effect on the front end. Passenger comfort has added. More NVH components More Infotainment systems. At the same time Fuel prices and pollution have driven Caf/CO2 and MPG legislation globally. More stringent Emission control. Fuel economy a bigger customer concern. So. We cant continue to keep adding mass, or larger engines to haul this mass around. G. Smith, Magna Steyr China International Symposium on Automotive Lightening Technology 8 Secondary Weight Reduction Primary Weight Reduction Reversal of the Weight Spiral Downsizing of Engine, Powertrain Secondary Effects By reduced fuel tank Detail lightweight Design in all domains Initialization by Body, Exterior and Interior China International Symposium on Automotive Lightening Technology G. Smith, Magna Steyr Secondary Effects by Chassis , brakes, . New Vehicle Architecture Lightweight Material Increase In Performance Density Integrated Lightweight Functional System Function Integration from External Sources NEW MATERIALS Material NEW COMPONENTS + Geometry + Optimized Function NEW SYSTEMS + Function + Functional Integration NEW ARCHITECTURE Multi-Disciplinary Lightweight Concept Different Approaches for Weight Reduction REDUCED HARDWARE Connectivity I2C+ Bring your own device Only a unified approach will lead to the most efficient weight usage 10 China International Symposium on Automotive Lightening Technology G. Smith, Magna Steyr Body in White Concepts Cost Spaceframe Aluminum/Steel Low Volume Mid Volume High Volume Spaceframe Aluminum/Carbon Monocoque Carbon Unibody Multi-Material Unibody Steel/Aluminum Unibody Steel CO2 Reduction, Sustainability Performance, Prestige Volume optimized architecture Performance oriented material selection Design to Cost Solution 1,000 +100,000 10,000 China International Symposium on Au