Assessing the Cost & Benefit of Effective Lightweighting Technologies

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This report examines why lightweighting may be a viable solution and examines the cost of lightweight automotive closures. This research analyzes the direct manufacturing cost by modeling the manufacturing processes of the door-in-white subsystem, including the inner and outer panels, hinge reinforcements, and intrusion beams, concluding with the joining of components into the subassembly, which can be installed in an automobile assembly plant body shop.

This project was developed by two student interns at CAR, supported by a grant from the Alcoa Foundation. Their work resulted in an extensive cost model with validation of the model through five case studies. A study of the lightweight door options is also included. This study includes breaking down the factors and costs of manufacturing lightweight doors, without consideration of the effect on mass decompounding or secondary weight savings. It evaluates which rules of thumb and published statements are supported, or challenged by our research. It concludes with recommendations based on research and case studies where the results come out of the cost model.