Automotive Engineering - September 2023 - 22

LIGHT,
T
FANTASTIC!
Plastics, steel and
aluminum technologies that
reduce weight and emissions
recognized with 2023 Altair Enlighten Awards.
by Ryan Gehm
oyota and its segment-first IsoDynamic Performance Seat
were big winners in this year's Altair Enlighten Awards, honored
during an awards ceremony at the 2023 CAR
Management Briefing Seminars (MBS) in August. Debuting in
the 2024 Tacoma TRD Pro, the performance seat's various lightweight
structures took the top spot for both the Enabling Technology
and the Module Lightweighting categories.
Four other category winners, along with runners-up and honorable
mentions, showcased how automotive and commercial-vehicle companies
are applying advanced technologies and artificial intelligence
to create a more sustainable future for the industry. " They demonstrate
exceptional leadership in this area, but more importantly they
demonstrate how these innovative solutions can be achieved by collaborating
with the supply chain, " Richard Yen, Altair's senior VP for
product and strategy, said at the ceremony in Traverse City, Michigan.
" We are seeing a lot of companies bring the suppliers together to
[drive] innovation, which serves as an inspiration for all of us who
would like to make a commitment to a better future. "
As companies increasingly electrify their product portfolios, lightweighting
efforts must continue, Alan Amici, president and CEO,
Center for Automotive Research (CAR), stressed. " EVs are heavy.
They are as much as 1,000 kg [2,205 lbs.] heavier than their ICE
counterparts, " he reminded the MBS audience. " Of course, we know
from our work in fuel economy that weight is directly [related] to
range. Just because we're moving away from CO2-generating propulsion,
we still have to be thinking about how to make vehicles lighter. "
Lightweighting Enabling Technology
Winner: Engineers at Toyota worked closely with counterparts at
BASF and US Farathane on what they claim is the world's first adop22
September 2023
Toyota's segmentfirst
IsoDynamic
Performance Seat
that debuts in the
2024 Tacoma TRD Pro
includes lightweight
structures that won in
two categories.
tion of a resin frame, as used for the IsoDynamic
Performance Seat in the 2024 Tacoma TRD Pro. Toyota
converted more than 17 multi-piece steel parts into
just one molded part, resulting in an estimated 20%
cost reduction and a 30% weight reduction, while
passing all front-row seat requirements. Another
claimed first is the adoption of lateral, vertical and
horizontal dynamic motions, with adjustable dampers
for the driver and passenger seats in off-road vehicles.
Injection molded by US Farathane, the seat structure
uses a combination of BASF's Ultramid impact-modified
polyamide grades. Using BASF's Ultrasim CAE
program, the seatback and cushion structural design
optimization creates a suspension system that ensures
lateral rigidity in resin frames while improving the seat
occupant's ride. Innovation throughout the process has
" massive potential " for other applications, according
to BASF's Kipp Grumm, senior technical development
engineer, Performance Materials. " The unique design
of the injection-molded resin seat frame can open the
door for future projects in offroad vehicles, " he said.
Runner-up: Chinese EV maker NIO applied high-pressure
die casting (HPDC) material and processing methods
for the rear-floor structure of its 2023 ES6 electric
SUV. The company used a new alloy material that does
not require heat treatment, as well as a more accurate
and efficient laser cleaning process. These changes resulted
in a reduction of part mass by 31%, reduced part
count by 98% (54 stamped parts replaced by a single
part!) and a 60% improvement in manufacturing time.
AUTOMOTIVE ENGINEERING
TOYOTA
Automotive Engineering - September 2023

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