Electric vehicles, like the Chevy Bolt, use materials such as aluminum, magnesium and carbon fiber to drive down curb weight.
Vacuum Diecasting Replaces Steel Stamping
Part Count Reduction: 5 pieces to 1.
Weight reduction: 20% mass savings.
• Vacuum diecasting creates high quality parts with high structural integrity.
• The aluminum casting design gave engineers flexibility to design more efficient attachment points.
• Smart tooling design helped the supplier make more parts per cycle.
Ductile Iron Replacing Aluminum
Part Count Reduction: Same.
Weight reduction: 6 lbs.
• Hollow design helped reduce mass.
• The ductile iron alloy chosen offers high ductility and toughness so thinner walls could be used.
• Casting solidification simulation ensured a smooth and rapid setup for production.
Steel Stamping to Magnesium Casting
Part Count Reduction: 7 parts to 2.
Weight reduction: 19.4 lbs.
• Elimination of spot welding.
• Strengthening ribs for required stiffness with less overall mass.
• Fluidity of magnesium made casting thin sections possible.
• Tool designed with internal heating and cooling to aid solidification.
Ford and General Motors worked with their casting suppliers to reduce vehicle weight with a variety of methods, from replacing material to switching processes.