Injection Moulding Asia Automotive Industry Generating environmental benefits from futuristic concepts eanwhile, hybrids are getting a facelift. Early this year, Ford debuted the C-MAX Solar Energi Concept, the first-of-its-kind sun-powered vehicle. Instead of powering its battery from an electrical outlet, the vehicle harnesses the power of the sun by using a special concentrator that acts like a magnifying glass, directing intense rays to solar panels on the vehicle roof. It takes a day’s worth of sunlight to deliver the same performance as the conventional C-MAX Energi plug-in hybrid, which draws its power from the electric grid. SunPower, which has been Ford’s solar technology partner since 2011, is providing high-efficiency solar cells for the roof. Because of the extended time it takes to absorb enough energy to fully charge the vehicle, Ford turned to Georgia Institute of Technology for a way to amplify the sunlight in order to make a solar-powered hybrid feasible for daily use. Ford says the positive environmental impact could be significant as it would reduce CO2 and other greenhouse gas emissions from the average US car owner by as much as 4 tonnes/year. Another sustainable design comes from Finnish company UPM’s Biofore, which is manufactured in partnership with Helsinki Metropolia University of Applied Sciences, the Finnish Funding Agency for Technology and Innovation and several other firms. It replaces plastics in many of the car’s parts utilising UPM’s biomaterials, such as the Grada thermoformable wood material for the passenger compartment floor, centre console, display panel cover and door panels. UPM’s Formi recyclable biocomposite, manufactured from cellulose fibre and plastics, is used to make the front mask, side skirts, dashboard, door panels and interior panels.
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Ford’s Lightweight Concept is part of its efforts to offer sustainable vehicle designs
US automotive maker Ford Motors recently launched its prototype Lightweight Concept vehicle, developed with the US Department of Energy and Cosma International, a subsidiary of supplier Magna International. It is about 360 kg or 25% lighter than a typical Fusion, thanks to changes in parts and materials. Thus, the instrument panel is made from carbon fibre and nylon composite, which is 30% lighter than steel; the rear window is made from polycarbonate, which is 50% lighter than glass; the windshield glass is made from a hybrid chemically toughened laminate, which is 35% lighter than glass. Furthermore, the seats are fashioned from carbon fibre frames instead of steel, while the aluminium brake rotors are 39% lighter than cast iron ones and carbon fibre wheels weigh 42% less than aluminium ones. Already, Ford has unveiled the 2015 F-150 pick-up truck, which is 320 kg lighter compared to the current version. Magna International also showcased its MILA Blue vehicle concept at the Geneva Motor Show early this year. The A-segment lightweight vehicle offers weight savings of 300 kg less compared to typical current A-segment vehicles. This comes from replacing the plastic interior trim with structural parts suitably designed with laminable, visually surfaces; utilising multi-materials, including aluminium, magnesium and composite materials, and leveraging smaller, lighter components. Furthermore, it is powered by natural-biogas producing less than 49 g CO2/km.
UPM’s Biofore car uses biomaterials in the interior
Furthermore, it is fitted with a modern internal combustion diesel engine and driven with UPM’s BioVerno, a wood-based renewable diesel, which can reduce greenhouse gas emissions significantly compared to fossil fuels.
MILA Blue achieves a weight savings of 300 kg, compared to typical current A-segment vehicles
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