Truck & Off-Highway Engineering - October 2023 - 9

TECHNICAL INNOVATIONS
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.
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
Future of Lightweighting: Marelli worked with Covestro on new polyurethane foam for interior products.
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 lb.). Positioned at
the front of the vehicle, the e-bracket 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
TRUCK & OFF-HIGHWAY ENGINEERING
October 2023 9
MARELLI

http://info.hotims.com/84505-706

Truck & Off-Highway Engineering - October 2023

Table of Contents for the Digital Edition of Truck & Off-Highway Engineering - October 2023

Truck & Off-Highway Engineering - October 2023 - Intro
Truck & Off-Highway Engineering - October 2023 - Sponsor
Truck & Off-Highway Engineering - October 2023 - Cover1
Truck & Off-Highway Engineering - October 2023 - Cover2
Truck & Off-Highway Engineering - October 2023 - 1
Truck & Off-Highway Engineering - October 2023 - 2
Truck & Off-Highway Engineering - October 2023 - 3
Truck & Off-Highway Engineering - October 2023 - 4
Truck & Off-Highway Engineering - October 2023 - 5
Truck & Off-Highway Engineering - October 2023 - 6
Truck & Off-Highway Engineering - October 2023 - 7
Truck & Off-Highway Engineering - October 2023 - 8
Truck & Off-Highway Engineering - October 2023 - 9
Truck & Off-Highway Engineering - October 2023 - 10
Truck & Off-Highway Engineering - October 2023 - 11
Truck & Off-Highway Engineering - October 2023 - 12
Truck & Off-Highway Engineering - October 2023 - 13
Truck & Off-Highway Engineering - October 2023 - 14
Truck & Off-Highway Engineering - October 2023 - 15
Truck & Off-Highway Engineering - October 2023 - 16
Truck & Off-Highway Engineering - October 2023 - 17
Truck & Off-Highway Engineering - October 2023 - 18
Truck & Off-Highway Engineering - October 2023 - 19
Truck & Off-Highway Engineering - October 2023 - 20
Truck & Off-Highway Engineering - October 2023 - 21
Truck & Off-Highway Engineering - October 2023 - 22
Truck & Off-Highway Engineering - October 2023 - 23
Truck & Off-Highway Engineering - October 2023 - 24
Truck & Off-Highway Engineering - October 2023 - 25
Truck & Off-Highway Engineering - October 2023 - 26
Truck & Off-Highway Engineering - October 2023 - 27
Truck & Off-Highway Engineering - October 2023 - 28
Truck & Off-Highway Engineering - October 2023 - 29
Truck & Off-Highway Engineering - October 2023 - 30
Truck & Off-Highway Engineering - October 2023 - 31
Truck & Off-Highway Engineering - October 2023 - 32
Truck & Off-Highway Engineering - October 2023 - Cover3
Truck & Off-Highway Engineering - October 2023 - Cover4
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