Technology: 5.5 - Design and Manufacturing Processes

5.Technology

- 5.1 Engine and Powertrain
- 5.2 Hybrid, Electric and Alternatively Fuelled Vehicles
- 5.3 Advanced Software, Sensors, Electronics and Telematics
- 5.4 Advanced Structures and Materials
- 5.5 Design and Manufacturing Processes

Integration

Systems integration is crucial if significant improvements to overall life cycle performance of road vehicles are to be achieved. This includes consideration of how the various vehicle sub-systems operate together, how the vehicle is designed, manufactured and operated, and how the information and knowledge that enables these systems to function can be combined more effectively and efficiently. The challenge will be to increase the level of integration in the design, manufacture, operation and re-use of vehicle systems in parallel to rapidly advancing technology and increasing complexity (engine systems, materials, electronics, software and communications), with increasing demand for more flexibility, agility and customisation. Standards, open systems architectures and metrics will need to be established, while at the same time ensuring that creativity and innovation are not compromised. Greater co-operation and collaborative knowledge sharing will be required, without compromising competitive advantage.

0-5 years	5-10 years	10-20 years
Modularisation of systems. e.g. front end module inc. Lighting, cooling, electrical, low speed crash, nvh. Easy parts change Multi-function structures – integrated electronics, switchable pigments etc More integration into component design Aim to develop multiple body configurations on single platform basis foolproofing for user changeover	Roof and/or door module including interior trim, exterior panel, plastic glazing, safety structure, nvh, ICE, antennae. Modular engines and transmissions Short term reconfiguration (leisure use etc)	High investment UHSS long life vehicle 'tub' with lower investment multi material modular subframe elements to achieve product diversity

Technology Targets

Technology target proposals appropriate to the DMaP group have been considered, and these are given in the following table. They should not been seen as definitive, but rather a view on suitable targets against which progress can be audited.

	0-5 years	5-10 years	10-20 years
Lifecycle	Component performance beyond single vehicle life Re-processing of metal mixtures to give pure metals for re-use Development of polymer separation techniques ELV and composite materials Attachment strategies for dismantling All technologies with a strong energy conservation/reduced waste/reduced resource element	Disassembly techniques Develop re-use mechanisms/methodologies Identify higher value markets for recovered materials National systems for material re-use and recycle Less than 2.5 years for engine Energy conservation 40% of 2005 on a like for like basis All products have a 90% recycling element	Less than 2 years for engine Long lifecycle will stifle new technology.
Manufacturing	Robust engineering solutions for rapid modular reconfiguration Reduce cost of moulded composites Faster, safer, more environmentally sound vehicle development Tooling life	Management of customer customisation and effect on design process/homologation and supply chainDevelop viable alternative to traditional paint finish for body panels
Integration	Component integration

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