Manufacturing Technologies Empowering Automotive Lightweighting

Additive Manufacturing and High Strength Materials Drive Opportunities for Lightweighting

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Lightweighting, one of the key trends witnessed in the automotive industry is expected to introduce transformational changes in the longer run. Lightweighting has garnered increased interest from the entire transportation ecosystem to improve fuel efficiency and reduce carbon emissions. Lightweighting of vehicles is achieved either by introducing design changes or by using advanced multi-materials either in the chassis, powertrain, engine or other interior parts of a vehicle. Lightweighting can significantly reduce vehicle weight, improve aerodynamics of the car, and enable improvement in the overall performance of vehicle. The technology and innovation report captures noteworthy manufacturing and materials rel

Table of Contents

1.0 Executive Summary1.1 Research Scope1.2 Research Methodology1.3 Explanation of Research Methodology1.4 Summary of Key Findings1.4 Summary of Key Findings (continued)2.0 Automotive Lightweighting – Landscape Assessment2.1 Lightweighting Trend can Improve Fuel Efficiency 2.2 How to Achieve Lightweighting of Vehicles?3.0 Key Materials Empowering Automotive Lightweighting3.1 What are the Key Materials Used in a Vehicle to Achieve Lightweighting?3.2 What are the Key Materials Used in Vehicles? 3.3 Is Carbon Fiber an Attractive Option for Reducing Vehicle’s Weight?3.4 Is AHSS an Attractive Option for Reducing Vehicle’s Weight?3.5 Advanced Materials and their Contribution to GHG Emissions 4.0 Key Manufacturing Technologies Enabling Automotive Lightweighting4.1 Parameters for Selecting Appropriate Manufacturing Technologies4.2 Technologies Enabling Automotive Manufacturing4.3 Categorization of Forming Technologies4.4 Extrusion Enables Multi-material Forming4.5 Flexible Roll Forming Enable Production of Complex Parts 4.6 Hydroforming Using Oil as a Fluidic Agent to Initiate Material Deformation 4.7 Forming Technologies Enabling Automotive Part Production4.8 Joining Technologies Commonly Used in Automotive Manufacturing 4.9 Magnetic Pulse Welding Generates Strong Weld between Multi-materials 4.10 Vibration Welding Addresses Challenges in Ultrasonic Welding 4.11 Welding Technologies for Aluminum Steel Joining4.12 Multi-Material Joining Technologies Without the Use of Heat4.13 Assessment of Joining Technologies and Suitable Combination of Materials5.0 Additive Manufacturing - The Way Forward For Automotive Lightweighting5.1 Segmentation of Additive Manufacturing/3D Printing Technologies5.2 Commonly Used 3D Printing Technology5.3 3D Printing Based on Bionic Patterns5.4 Composite 3D Printing for Automotive Prototyping5.5 Prospects for AM in Automotive Lightweighting 6.0 Market Potential and Adoption Assessment6.1 Automotive Lightweighting Market Opportunities6.2 Innovation Ecosystem6.3 Factors Influencing Innovation Trends and Initiatives6.4 Factors Influencing Adoption of Lightweighting Technologies6.5 Factors Hindering Development and Adoption6.6 Regional Assessment of Lightweighting Trend7.0 Assessment of Strategic Initiatives Driving Developments7.1 Partnerships/Alliances7.2 R&D Portfolio Areas7.3 Key Funding Initiatives and Trends8.0 Strategic Perspectives8.1 Emerging Growth Opportunities8.2 Technology Roadmap – Forecast till 20258.3 Key Conclusions9.0 Key Patents and Contacts9.1 Key Patents on Advanced Materials9.2 Key Patents on Aluminum for Lightweighting9.3 Key Patents on 3D printing for Automotive Application9.4 Key Patents by Branson Ultrasonics Corp9.5 Key ContactsLegal Disclaimer

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