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Filed under: Lightweight

Gordon Murray's Type-25 city car gets fleshed out

Filed under: Manufacturing/Plants, Lightweight

Since first hearing that ex-McLaren F1 supercar designer Gordon Murray had left the famous racing company to create his own design house and that its first product was to be a revolutionary city car, we've been anxiously awaiting more details to come to the surface. Lucky for us, they just have. Murray promises that his low-cost car will cut emissions in half and be cheap to purchase and manufacturer. In fact, twenty-percent fewer parts are said to be necessary for the assembly of the vehicle. So far, no real details on what will power the vehicle are available.

We do know that Caparo, makers of the extremely impressive T1 supercar, are heavily involved in the project. This leads us to believe that some major use of composites is in order as carbon fiber is a specialty of Caparo. Murray has no plans to actually produce the vehicle; instead he will sell the plans to other automakers for them to offer to the public. Interestingly, Murray also claims that shipping expenses will also be reduced as the vehicle can be flat packed Ikea-style.

[Source: Autocar]

2009 BMW 7-series leaks, possible hybrid coming in a year

Filed under: Hybrid, BMW, Lightweight



BMW is certainly no fan of the new corporate average fuel economy regulations and for the most part the new fifth generation 7-series debuting this fall is a big middle finger salute to the whole premise. Nonetheless, BMW is incorporating some technology to help the fuel efficiency of its flagship. The Munich carmaker is using aluminum for much of the suspension to help reign in the mass. The 7 is also expected to eventually get either the Two-Mode or mild hybrid systems that it has in development. So far the only vehicle that BMW has committed to equipping with the Two-Mode is the X6. The 7's main competitor, the Mercedes S-class, is getting the mild hybrid system that the two companies have co-developed.

At launch however, American customers are likely to only have one engine choice, the 4.4L twin-turbo V-8 that recently debuted in the X6. Elsewhere, drivers will also have the option of six cylinder gas and diesel engines. BMW has yet to announce any diesel plans beyond the 335d and X5 that are coming this fall. Both sixes are already used in other U.S. BMW models so they could easily be added to the 7. Given the new CAFE rules, it seems likely that the hybrid and six cylinder models will come to the U.S. sooner rather than later.

[Source: Automotive News - sub. req'd]

DIY electric motorcycle from New York

Filed under: EV/Plug-in, On Two Wheels, Green Daily, Lightweight, USA



An enterprising man in New York has managed to build an electric motorcycle which he's referring to as the Battery Box. This term comes from the design of the frame, which is just large enough to house the battery components and is built from aluminum for minimal weight. The batteries are a lithium polymer chemistry and offer 48 volts with 40 amp hours of power. Based on the voltage, we assume that the two electric motors are DC. One motor is hub mounted at the rear and provides 6kW of power while an additional, smaller 3kW motor adds some additional acceleration when called upon.

Front forks from an Italian moped contribute to the Battery Box Motorcycle's light weight. The builder claims that this bike represents his first design and a second, more refined machine will be offered for sale for an expected price of $8,000. Check out the video after the break for some more information. Thanks for the tip, Mark!

[Source: Battery Box Motorcycle]

VW supposedly still working on one-liter car - possible 2010 launch?

Filed under: Diesel, Hybrid, MPG, Volkswagen, Lightweight


Click above for more shots of the VW One-Liter concept

It has been so long since anything has been heard about Volkswagen's so-called one-liter car that we nearly forgot the concept had existed. It turns out that VeeDub has been quietly working away somewhere deep in Germany perfecting the design. Originally intended for a launch around 2012, rumors now indicate that the vehicle may indeed be ready by 2010. To refresh your memory, the vehicle gets its moniker due to its goal of achieving one liter of fuel consumption per 100 kilometers. The concept vehicle, with its single cylinder engine, was apparently capable of doing a bit better than that, as it was rated at a mind blowing 282 miles per gallon, or about .83 liters per 100 kilometers.

The production version of the carbon fiber vehicle may get a twin cylinder diesel engine along with a possible hybrid drive of some sort. For maximum compactness, the vehicle features the driver in the center of the car with one passenger sitting behind in a cockpit-like arrangement. No word as of yet on price, but it seems that VW is hoping that the government can step in to reduce the cost for purchasers.


[Source: Car Magazine Online]

Ferrari MilleChili concept to spawn production car

Filed under: Ferrari, Lightweight


Click above to view the Ferrari Millechili in our hi-res gallery

While some could rightly wonder what in the world a Ferrari supercar could do to be green, the fact that the Italian manufacturer of super high performance prancing horses cars is interested in cleaning up its act at all probably deserves a measure of commendation. After all, historic rivals Porsche and Lamborghini have proven to be rather stubborn when it comes to changing their ways.

Remember the Ferrari MilleChile concept we showed you last year? Current rumors predict that a vehicle using many of the ideas originally introduced on that cardboard cut-out will make it to production. Green aspects such as direct injection for the rumored V10 engine and lightweight carbon-fiber construction seem likely. Of course, those two aspects would have a desirable effect on performance as well, so we're sure there is more than just green ambitions at play with these rumors.

[Source: Car and Driver via Autoblog]

Bizarre car showcases lightweight materials and construction

Filed under: Emerging Technologies, EV/Plug-in, Lightweight, Japan



Topia Corp. has been showing off their lightweight electric car at the booth of Marubeni Information Systems Co Ltd at the 19th Design Engineering & Manufacturing Solutions Expo (DMS). Ok, maybe "car" is a little strong. This little one seater looks to have much more in common with that enclosed mobility scooter from Australia, the Rainrider. In any case, don't look for the "HUVO" to be having its way with streets or sidewalks near you any time soon. Its purpose seems to be to showcase the ability of its creators to design and build prototypes quickly using the lightest of materials and the geekiest of technologies and, at that, we think it succeeds where others fail.

Consider that this ovoid wonder weighs only 150kg (330 lbs) despite its high-tensile steel plate frame. According to Topia president and CEO, Hideki Sasaki, "If a vehicle of the same size as HUVO is made with existing technologies, it would weigh about 300kg (660 lbs)". They accomplish this feat by using aluminum alloys, carbon fiber reinforced plastic, and ABS resin. The windshield is polycarbonate instead of glass. The actual building techniques are also impressive. The company designed and built its own press molds and utilized equipment ranging from lasers to a rapid prototyping system. The only thing lacking in this concept is the concept of "sexy".

[Source: Tech-On via Engadget]

Mazda declares it will cut consumption by 30% by 2015

Filed under: Diesel, Hydrogen, MPG, Mazda, Lightweight

Mazda has declared that by the middle of the decade they will have replaced their entire powertrain lineup and cut fuel consumption by 30 percent. On the powertrain side, engines will be upgraded across the board including a new direct injected wankel rotary. In 2009, a new Smart Idle Stop system will debut that restarts the engine using the direct injection system instead of the starter. Fuel will be sprayed directly into the cylinder and ignited to get the pistons moving. New gas engines will get direct injection and Mazda will add new clean diesels to the lineup worldwide as well as continuing to develop hydrogen-fueled engines.

Ford's Japanese affiliate intends to continue down the path begun with last years new Mazda2 and the new 6 this year by reducing the weight of new models. The trend of recent decades to higher powered engines has led to a cascading effect of increased mass to support the power. Mazda intends to reverse the process. From 2011, Mazda wants to cut at least 220lbs from new models.

[Source: Mazda]

High School students build enclosed electric motorcycle

Filed under: EV/Plug-in, On Two Wheels, Green Daily, Lightweight, USA


Click above for more shots of the Saint Thomas EV

BMW once came up with the idea to enclose a scooter and add some safety equipment to it. Crash tests showed surprisingly favorable results, but the idea never seemed to catch on and the C1 is no longer for sale. The fact that it already proved unsuccessful on the commercial market once hasn't stopped others from considering the idea. One such group is the Saint Thomas Academy in Mendota Heights, Minnesota. A group of students at this high school has created an enclosed electric motorcycle which uses sixty volts worth of lithium phosphate batteries powering a Briggs and Stratton ETEK pancake-style permanent magnet electric motor.

The current configuration is said to be good for a top speed of sixty miles per hour and a range of forty miles. The chassis is constructed from chromoly tubing. The body is made from a carbon fiber and Kevlar composite and should therefore prove very strong. The full seat even features a seatbelt. We are not certain that anything quite like this will ever be available for purchase again, but its good to see it in concept form at least.


[Source: The Kneeslider]

Lightweight Hungarian three-seater gets 117mpg in the city!

Filed under: MPG, Lightweight



Hungary is not generally known as a hotbed of automotive development, although Audi does have a factory there that builds many of its engines. A new prototype vehicle from the former Soviet block state, though, provides a very interesting look at some possible future transportation.

The Antro Solo combines some of the best ideas from legendary race car designers like Colin Chapman and Gordon Murray with concepts from solar racers, mopeds and Priuses. Living up to Chapman's mantra of "adding lightness" the Solo weighs a mere 600 lbs thanks to a composite construction. Clever packaging with two passenger seats on either side of a central driver's throne a la Murray's Mclaren F1 are blended with diesel-electric hybrid powertrain. The battery gets some range extension from roof top solar cells and pedals for the passengers. Antro is targeting an $18,000 sticker and 117mpg city/157mpg highway specs. With those kinds of numbers, this could be an X-Prize winner. Unfortunately, the carbon fiber body alone is likely to cost more than $18k and, at 600lbs, passing any kinds of safety standards anywhere in the world is going to be nearly impossible.

[Source: AutoFiends]

Toyota believes it has higher iQ

Filed under: SMART, Toyota, Lightweight, Japan, USA


click the Toyota iQ for high res gallery

With the rather healthy sales numbers currently being posted by the smart fortwo in the U.S., Toyota seems very excited about the prospect of offering its iQ here. Still, the tiny car will be launched first in Japan, followed by Europe at the beginning of next year. High gas prices seem likely to sway Toyota to consider the diminutive machine for America, though. According to chief engineer Hiroki Nakajima, Toyota's iQ could be a bit higher than smart's, as the Japanese model will feature two extra seats and should post better fuel economy numbers. Like the smart, though, it will be priced more in line with the current crop of small cars and is not meant to undercut them in price. Instead, the iQ is to offer a premium driving experience.

In Europe, the iQ will be offered with a 1.4 liter diesel engine. If the model ever makes it over here, count on either the 1.0 or 1.3 liter gasoline engine underhood. If that does indeed happen, will we ever get tired of making ridiculous puns about the iQ and smart names? Nah.


[Source: Automotive News - sub. req'd]

Dodge Hornet likely to be built by Nissan

Filed under: Chrysler, Dodge, Nissan, Lightweight, USA



As we reported the other day, Chrysler is working as hard as possible to get its gas-guzzling fleet more in line with consumer desires. These days, that means fuel efficiency, so it comes as little surprise that Dodge is renewing its efforts to get the Hornet small car up and running. Up until this point, it had been assumed that the Chrysler joint venture with Chinese automaker Chery would produce the Hornet, but it seems that the Chinese company may not be quite ready for prime time. Instead, Chrysler's recent tie-up with Nissan is now expected to result in the new Dodge vehicle.

Chrysler still has plans to introduce a budget line of vehicles with its Chinese counterpart. Dodge's upcoming Hornet, though, will not be an entry level model at all. The Hornet is expected to compete with upper level small cars such as the Mini, which has seen excellent sales as of late due to its fuel efficiency.

[Source: Automotive News Europe - sub. req'd]

Quantum will design advanced powertrains for Future Steel Vehicle program

Filed under: EV/Plug-in, Hybrid, Hydrogen, Lightweight

Quantum has been working on adding hydrogen capability to the Norwegian infrastructure, both through hydrogen stations and converted hydrogen Priuses. In the U.S., Quantum is also working on plug-in hybrids for California's South Coast AQMD. Last week, Quantum Fuel Systems Technologies Worldwide announced it will now be working on new advanced hybrid powertrains for EDAG and IISI. Who? Glad you asked.

IISI is the International Iron and Steel Institute, which has an automotive group, and EDAG is the Engineering + Design AG. The two are involved in the Future Steel Vehicle program, which hopes to find new, lightweight steel autobody concepts that are designed to work well with new vehicle powertrains, be they plug-in hybrids or hydrogen fuel cell. Quantum's task is develop the powertrains (advanced lithium-ion battery system and controls) with partner Advanced Lithium Power Inc. All of these concepts are meant to show that old-school steel is not dead yet (in fact, I heard it's going for a walk). Don't think the Rocky Mountain Institute will be in favor of that. Details after the jump.

Pilgrim International begins producing composite RVs

Filed under: Etc., Lightweight, USA

As was just pointed out on this very blog the other day, the Recreational Vehicle (RV) market has been hit extremely hard by the recent rising fuel prices. As you have probably noticed yourself, diesel prices have seen rather unprecedented increases, and it's these large and powerful vehicles which are often used to pull trailers. Manufacturers of RVs which are not powered themselves can do little when it comes to increasing the efficiency of the vehicle doing the heavy lifting, but they can lower the weight of the trailer itself, which, of course, will only help when it comes to overall fuel efficiency. To that end, Pilgrim International has created two new lines which rid the trailer of wood structures and replace them with lighter-weight composites. Though RVs have been using fiberglass composites for years, most of the structure was still made from wood and steel. In one case, the structure was lightened so much that its steel chassis could be lightened by six-hundred pounds. We'd expect to see more companies follow in the path of Pilgrim when it comes to the lightening of the load.

Full-size SUVs from GM to get lighter

Filed under: Manufacturing/Plants, Chevrolet, GM, GMC, Lightweight


Click above for more high-res shots of the Chevy Tahoe Hybrid

It was only a few years ago that General Motors was bullish on the U.S. market for full-size, body-on-frame sport utility vehicles. Today? Not so much. These days, the bottom has fallen out of the big truck market, as even the once untouchable Ford F-150 has seen its perch atop the sales charts come to an abrupt halt. While there will always be a certain number of people who truly need the vast capabilities of the largest of trucks, that demographic is shrinking alarmingly quickly. In lieu of this fact, General Motors may begin phasing out its full-size SUVs. Because this may point to new SUVs from the General using unibody architecture, the future of family stalwarts such as the Suburban and flavor-of-the-day models such as the Cadillac Escalade are in doubt.

We don't expect GM to abandon the market totally, as sales, though down, are still strong enough to warrant the models' place on dealer lots. We do, however, expect that more fuel efficient gasoline engines, diesels and hybrids will join a lighter-weight structure as the long-term future unfolds.

[Source: Automotive News - sub. req'd]

VIDEO: Examining the design compromises in the Tata Nano

Filed under: MPG, Lightweight


Click on the photo to watch the BBC video of the Nano engineers


When you set out to produce a car at one-third the cost of anything else on the market, a lot things invariably need to be left behind. Creating a car like the Tata Nano requires taking a complete top down look at every system in the car. Every component needs to be analyzed to make sure it's really needed. For example, instead of the usual four or five lugs, the wheels of the Nano use only three. Given the low power and light weight, this is sufficient. Not only does it reduce the part count, it also reduces the time required to assemble the car. Other examples of parts reduction and simplification appear in the door handle mechanism which now has half the number of parts. Of course all this simplification runs the risk of reducing reliability and durability. Only time will tell if the Tata engineers have gone too far. For more, watch as the BBC takes a look at how Tata created the Nano.

[Source: BBC, thanks to Misha for the tip!]

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