Automotive Engineering - September 2023 - 23

COVER STORY
Module Lightweighting
Winner: Toyota, with its supplier partners Adient and
Multimatic, again won for innovations employed in the
IsoDynamic seat. Its structure is made using
Multimatic's proprietary Accra technology, a high-volume,
hot-form manufacturing process that uses form
blow-hardening (including rapid water quenching) to
manufacture ultra-high-strength boron steel. The process
helped to reduce mass by 17% and packaging
space by 40% - and it also increased torsional load
strength in key areas by 30%.
Accra structures have been used for sport bars and
front-bumper reinforcements, for example, but the
seat application is new. " Luckier than good is a great
thing, " a Toyota engineer said at MBS. " Multimatic just
happened to be in the office doing a presentation. I'm
like, 'I need that. We need to put it somewhere else.' "
Runner-up: Nemak developed a new alloy material for
high-pressure die casting (HPDC) that reduced the overall
weight of BMW's e-bracket by 30% compared to a
starting design, resulting in a final weight of 16.74 kg
(36.9 lbs.). Positioned at the front of the vehicle, the ebracket
is a central carrier for EV powertrain components
such as the electric motor, inverter and compressor.
Future of Lightweighting
Winner: Marelli developed a new, lightweight polyurethane
foam that can be applied to all foam-in-place
(FIP) applications, particularly the main dashboard
panel. It reportedly reduces part mass by 40% with
new tooling, or 8% with current tooling, and decreases
foam thickness by 50% to support styling aesthetics.
The new foam, the result of a joint development with
materials partner Covestro, also cuts raw material
costs by 20% and volatile organic compounds by 80%
compared to the current polyurethane foam in use,
while retaining a high-quality feel and appearance.
The project began during the Covid-19 pandemic.
" We set out with a 25 percent weight-reduction target.
Enabling Technology: Injection-molded
seatback and seat cushion developed by
Toyota, BASF and US Farathane.
With our first trials in future production tools, we found that it exceeded
that target - that blew our socks off, " a Marelli representative
said at MBS. " The key metric to us was actually having it be reverse-compatible
to current tooling and programs so that we can
deploy this in the current vehicles. "
Runner-up: Ajedium PEEK slot liners developed by Solvay
Specialty Polymers can reduce battery-pack weight by 12 kg (36.4
lb.) and the e-motor by 4 kg (8.8 lb.). There is no requirement for
high-power dedusting equipment or climate-controlled storage to
prevent moisture uptake (reducing energy consumption), since PEEK
slot liners can be inserted using existing equipment.
Honorable Mention: WorldAutoSteel and engineering partner Ricardo
developed steel body structures for a fully-autonomous vehicle concept
that meets stringent crash requirements. The concept features a 282-kg
(622-lb) body structure and a 25% mass reduction compared to an expected
reference vehicle, the organizations claim. It also has the potential
to reduce total lifecycle carbon emissions by 86%.
Honorable Mention: Michigan Technological University created a
steel e-motive side closure mechanism as part of the Auto/Steel
Partnership. The mechanism uses advanced high-strength steel
(AHSS) instead of aluminum, potentially cutting carbon emissions by
3X while also reducing manufacturing costs.
Future of Lightweighting:
Marelli worked with Covestro
on new polyurethane foam for
interior products.
AUTOMOTIVE ENGINEERING
September 2023 23
FROM TOP: BASF; MARELLI
Automotive Engineering - September 2023

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