Light-car designers compete with heavyweight automakers

By Bill Bregar
Senior Staff Reporter

Published: December 27, 2012 6:00 am ET

Edison2’s prototype electric Very Light Car was based on the VLC above, which runs on gasoline. Its 100 mpg EPA rating for average distance traveled per unit of energy consumed helped it win the $5 million X Prize from Progressive Insurance in 2010. (Edison2 photo)

Related to this story

Topics Materials, Suppliers, Sustainability, Automotive

Kuttner joined Tata Technologies Ltd. designers Peter Davis and Raymond Peters, and Gregg Peterson from Lotus Engineering, to talk about super weight savings, during the conference, organized Nov. 6-7 by Plastics News in Livonia.

Kuttner calls the X Prize winner the Very Light Car. He thinks that within five years, Edison2 will produce about 10,000 cars a year in the United States. Since the car can be assembled in a warehouse-type structure, with a simple modular structure, he said the VLC could become a world car.

Peters, senior program manager at Tata Technologies, agreed with Kuttner about starting with a clean sheet. “The approach that has to be taken is not to start from what we know and change it. You have to start from zero and build it from there. It’s a completely different way of approaching the problem,” he said.

At the lightweighting conference, Tata displayed an eMo concept car (for electric mobility), sporting thermoplastic body panels with molded-in color.

There are no welded parts; everything uses mechanical assembly.

The most obvious innovations are a panoramic windshield and roof, with no roof pillar, and an integrated rear window/rear light assembly, all made of polycarbonate. There is no trunk, but the rear seats flip down for storage space, Peters said.

Peters and Davis work at Tata Technologies’ facility in Novi, Mich. Engineering teams from North America, Europe and India collaborated on the eMo. Tata Technologies is part of Tata Group, which also includes the Indian carmaker, but they work independently, with any automaker.

The eMo could get the equivalent of 150 mpg and carry four adults. In production it would cost about $20,000.

“To achieve what we attempt to do, you could not start with an existing vehicle,” Peters said.

A Lotus Engineering Ltd. study showed a combination of materials — aluminum, magnesium, plastic and steel — will be a key to reducing weight, said Gregg Peterson, senior technology specialist. He gave examples of sandwich structures to give high strength, crash resistance and weight savings. Coated plastic parts can be used under the hood.

Peterson is a member of a Lotus team that developed a vehicle body structure 37 percent lighter than one with a steel body. Lotus Engineering is part of Lotus Cars of Norfolk, England.

“One of our goals was to have each part have two or three functions — multiple functions for every part,” he said.

Ultralight aerogels foams give thermal insulation and acoustic dampening, Peterson said.

Kuttner said the engineers of the Lynchburg, Va.-based Edison2 focused on taking out weight and mass. “We reinvented what a car is,” he said.

One key development was creating a suspension system that fits entirely inside the wheels, instead of under the car, significantly cutting weight and taking up much less space, and allowing a flat floor by getting rid of the strut tower. “This suspension, we believe, will find its way into a number of production cars in the near future,” Kuttner said.

Kuttner also thinks plastics has a good future, not just from lightweighting, but because of social changes like car-sharing services in big cities.

“Plastic cars are going to become more popular, because people are going to give up the detail of the great personal palace of a car, to something that’s easy and quick and convenient that you can use for a few hours and hand back,” Kuttner said. “Then somebody has to clean it, so plastics are definitely going to start to take over there because they can be designed to be more friendly for things like that.”

Kuttner, a real estate developer and race car enthusiast, said big car corporations keep their engineers in a straightjacket when it comes to radical changes needed to meet the corporate average fuel economy — or CAFE — standards.

“You have to be allowed to be free. And there are a lot of great engineers out there,” he said. “I think this shift will destroy some companies, and it will be also a great opportunity for the industry, a great opportunity of careers. It’s the great opportunity for plastics.”

Kuttner acknowledged his team’s roots in racing, where bigger and faster is better.

“But we’re also humans. I actually believe that a consumer is perfectly happy to accept something slightly less than a Class A finish, if the price is right, and the service is right, and everything else works. And at that point, plastics are really special, and the tipping point is there.”

See Plastics News' video coverage of Plastics in Lightweight Vehicles, including interviews with light-car designers, at plasticsnews.com/video.


Comments

Light-car designers compete with heavyweight automakers

By Bill Bregar
Senior Staff Reporter

Published: December 27, 2012 6:00 am ET

Post Your Comments


Back to story


More stories

Image

Dunkin' Donuts looking at PP to replace foam cups

September 19, 2014 3:22 pm ET

Dunkin' Donuts is testing a new polypropylene coffee cup that the company believes could help boost recycling.    More

Image

Plasan investing in capacity, jobs to supply auto market with carbon fiber

September 19, 2014 3:05 pm ET

Growth in the emerging automotive market for carbon-fiber composites has spurred a $29 million investment in a Walker, Mich., factory    More

Image

Hong Kong's TK eyes expansion, may buy Nypro Tool operation

September 19, 2014 2:49 pm ET

Hong Kong-based mold maker and plastics processor TK Group (Holdings) Ltd. said it's reached a tentative agreement to buy a tooling factory in...    More

Image

Toyoda Gosei expanding in Mexico

September 19, 2014 2:33 pm ET

Toyoda Gosei North America Corp. is investing $67 million in a 398,000-square-foot plant in central Mexico to supply the automotive industry with...    More

Exo-s buys injection and blow molder in Mexico, expands footprint

September 19, 2014 2:15 pm ET

Custom molder Exo-s Inc. has bought an injection and blow molding operation in San Juan del Rio, Querétaro, Mexico.    More

Market Reports

Plastics Caps & Closures Market Report

The annual recap of top trends and future outlook for the plastics caps & closures market features interviews with industry thought leaders and Bill Wood’s economic forecast of trends in growing end markets. You will also gain insight on trends in caps design, materials, machinery, molds & tooling and reviews of mergers & acquisitions.

Learn more

Shale Gas Market - Analysis of North American Region

This report highlights the impact of shale-based natural gas on the North American plastics market and features an in-depth analysis of production trends in the United States during 2013 and a forecast for 2014 and beyond.

Learn more

Thermoformed Packaging 2014 Market Review & Outlook – North America

This in-depth report analyzes economic and market trends, legislative/regulatory activity impacting supply and demand, business opportunities and threats, materials pricing, manufacturing technology, as well as growth strategies being implemented by thermoformed packaging companies.

Learn more

Upcoming Plastics News Events

January 14, 2015 - January 14, 2015Plastics in Automotive

February 4, 2015 - February 6, 2015Plastics News Executive Forum 2015

More Events