Smarter, Lighter Car Design: A 2017 Automotive Manufacturing Report
As technology evolves, the way we design cars is also evolving; with heightened awareness of manufacturing’s impact on the environment and the increasing interconnectivity of devices through the Internet of Things (IoT), automobiles are becoming both lighter and smarter.
Creating New Designs to Meet New Regulations
Experts project steady growth in light vehicle sales over the next 10 years, as manufacturers worldwide are increasingly focused on building more fuel-efficient vehicles. In fact, as fuel economy regulations continue to tighten, U.S. and European automakers will be expected to average more than 60 miles per gallon by 2025.
American auto manufacturers have begun using lightweight materials as the first step toward achieving this goal, and it’s already paying off. When Ford reduced the weight of its F-Series trucks in 2014 by swapping out steel for aluminum, the following year’s F-150 had the best mileage of any gasoline pickup in the United States — all while maintaining its position as the best-selling domestic vehicle of any kind (by a large margin).
The same principles of fuel efficiency also apply to all types of smaller components used in these vehicles. For example, CGR recently developed a solution for Ford diesel truck engines that were experiencing shutdowns during snow and ice conditions; any time the air filter intake area was clogged with snow, the engine would use excess fuel and eventually shut down from a lack of air flow.
To resolve this issue, we supplied a waterjet-cut urethane airflow solution, adding an 80-PPI (pores per inch) filter foam to allow the passage of air, regardless of environmental conditions. Our team provided five different prototype parts in various shapes and porosity levels. The final version, selected by Ford, is now in full production for all their diesel truck models.

Even small design tweaks can have major environmental impacts
As another example, our 3M Thinsulate — an alternative material choice for acoustic automotive applications — greatly enhances sound insulation and acoustic absorption without adding unnecessary weight to a vehicle. Simply adhering a few square centimeters of this polyester and polypropylene non-woven fiber blend to a car’s interior panels, seatbacks, doors, luggage compartments, HVAC equipment, and engine undercovers allows for improved functioning without added weight.
As the push for sustainability continues, you’ll notice that modifying even the most basic parts of a car can improve its fuel efficiency. To meet changing regulations, forward-thinking automakers and car component contract manufacturers have already begun adjusting their designs accordingly.

Establishing New Processes for Shifting Demands
The rapid assimilation of technology into smart cars means automakers are working more closely with tech companies — and being forced to reconcile their distinct design processes. While automotive manufacturers typically like to take their time developing one product before moving forward with high-volume production, software companies prefer to “fail and fix” through a rapid prototyping process. To successfully integrate with the latest technologies, car makers will need to quicken their design processes to match.
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We hope you find this information helpful as you hone your business strategy for 2017.
Any questions about emerging auto trends? Contact us today to learn more.