Study: 18% Lighter Vehicles Feasible in Five Years

Carmakers could reduce the weight of their next-generation light-duty vehicles 18% as soon as 2017 without raising production costs or reducing performance and crashworthiness, according to a report for the U.S. Environmental Protection Agency.

The study was conducted by FEV Inc., the German engineering services provider, which says its analysis is the most comprehensive to date. The heavily illustrated 878-page report, Light-duty Vehicle Mass Reduction and Cost Analysis Midsize Crossover Utility Vehicle, can be downloaded in PDF format HERE.

The study, which uses the 2010 Toyota Venza crossover as its base, says the vehicle's weight could realistically be cut 312 kg (688 lbs) by 2017-2020. Major contributors would be techniques that lighten the suspension by 28%, interior by 19%, body-in-white by 13% and powertrain/brakes by 5%.

Earlier research by others considered reducing vehicle weight by substituting materials and modifying structural design. FEV's study expanded that scope by including methods of lowering powertrain mass.

More important, FEV evaluated weight-saving options against requirements that changes not increase production costs or reduce safety or vehicle performance. The study used advanced computer-aided engineering tools to analyze options.

FEV says reducing a vehicle's mass by the 18% deemed feasible for the Venza also would add $23 million in tooling costs but reduce direct manufacturing expenses by $148 per vehicle.