Lightweight automotive body structures gain ground

Lightweight door system manufacture, involving "hybrid" technologies, is making inroads into some of the leading European automotive brands.

Wagon plc's lightweight door system technology is making inroads into some of the leading European automotive brands.

The company can count PSA, Daimler Chrysler, Renault, VW and Audi amongst its customers.

It is also supplying lightweight door systems to Jaguar.

Some of the models being supplied, such as Audi's A4 and A6, are produced in volume; others, such as the work for the Phaeton and Maybach, involve extremely small production runs.

Volumes for the lightweight systems range from around 1,000 a year up to nearly 300,000, but are typically between 20,000 and 100,000.

The technology involves the ability to design and build crashworthy door systems, often with complex frames, in aluminium.

Manufacturing work involves "hybrid" technologies: some projects call for multi-axis stretch bending capability (an aluminium extrusion can be bent in up to nine axes simultaneously), as well as stamping and welding, to allow structures to conform to the flowing aerodynamic and "lifestyle" designs of modern vehicles.

For Wagon, which has transformed itself into a focused engineering group specialising in the design, engineering and manufacturing of lightweight automotive body structures, its ability to attract interest for the door system technology from a list of prestige manufacturers is being regarded as solid evidence of strategic success.

The St Gauburge plant in France has been the subject of a long-term investment programme to make it one of the most capable automotive aluminium facilities in the world for the creation of lightweight vehicle structures.

However, work is done at locations throughout Europe, and Wagon has engaged in extensive technology transfer to ensure that plants closest to the customer's location are equipped to fulfil a contract.

"Manufacturers have made huge strides in drive train technology to meet the emissions and environmental challenges which they must face in the coming decade," said Wagon Group Chief Executive Nick Brayshaw.

"However, the targets they have set themselves are not going to be achieved unless they take weight out of the primary structure of the vehicle.

"It is our mission to help our customers achieve that, and we have spent some years re-structuring the group to ensure that we can deliver real benefits cost effectively.

The progress we are currently making in terms of servicing OEMs in Europe is evidence that the long term plan is coming together.".

Back to top