Suitable material development is key to achieving the reduction of environmental impact of vehicles, particularly at end-of life, where targets for re-use and recycle are set by European Directives. The list of substances prohibited either for their environmental impact or direct health effects is ever increasing, such that all materials developed for use in vehicle manufacture need auditing for suitability at the outset. Consideration of needs for re-use and recycling requires a systems approach for “cradle to grave” component management, including design for disassembly and reprocessing. Polymeric materials in particular need consideration for this purpose. The environmental effect of processes also impacts materials, with a challenge for materials that can reduce or eliminate processes with a high environmental impact having costly control needs, such as paintshops.
0-5 years
5-10 years
10-20 years
Life cycle issues closely adhered to
Low cost integration of lightweight composites into commercial sector (bodywork)
Environment on the next NCAP
Provide low cost alternatives to surface treatments which are now prohibited
Challenges for EOL recycling will require single piece as opposed to multi-piece assemblies
Low cost manufacturing of large, lightweight commercial vehicle chassis Structural materials contribute to noise reduction
Enable repair techniques for UHSS, aluminium and other low weight structural materials
Emphasis on re-use rather than recycling for key components, with appropriate systems in place
Improved high strength lightweight structures
Magnesium alloys used in a wider range of applications for weight and dampening (powertrain, A & B pillars)
Design to withstand damaged roads Weight saving emphasis in parallel with take-up of new fuels, fuel cell, hybrid etc.
Manufacturing Systems
Development of suitable manufacturing systems to design, join, and assemble vehicles in a shorter timescale is driven by the needs for a competitive industry giving suitable profitability. Linked to this are the needs for modularisation associated with product configurability and flexibility, as well as the demands for easy disassembly for re-use and recycling at end-of life, together with systems suitable to unlock the potential of newly developed materials and structures.
0-5 years
5-10 years
10-20 years
Design for dismantling
Modularisation
Component re-use
Off-line virtual prototyping
Manufacturing to order
Shared production facilities between OEM’s to equalise production rates as customer demand varies
Initial appearance of low volume vehicles with some elements of mass customisation.
Reductions in product development time to market.
Wider use of magnesium and its alloys as the understanding of material and techniques increases
Alternative material/coating combinations to make paint shop redundant for corrosion and cosmetics
Manufacturing process simulation tools to avoid expensive surprises (and data to enable them to work)
Product updating
Contract assembly infrastructure
Cost model for production methods change
Ease of repair to damaged vehicles
New materials and structures developed for low volume products
Only very large volume vehicles use “Budd” type assembly. These will be customer configurable and possibly modular
Lower volume vehicle using low investment techniques - will be customisable and modular (including electrical system, A/C ducting etc in structure)
Micro factories
Flat pack.
