06/06/2011

Schuler helping cars become lighter. The result: lower fuel consumption, fewer CO2 emissions.

Our cars have gotten heavy. This is confirmed by an analysis of their development over the past few decades: the empty weight of compact class cars, for example, has doubled since they first appeared on the market. This has virtually nullified all progress made in producing more economic engines. Innovative lightweight construction strategies, however, can help reverse these spiraling weights. The Schuler Group is the world’s only press manufacturer to supply manufacturing technologies and fully automated systems solutions for all production processes in the field of lightweight car body construction.

Studies have shown that a reduction in car weight of 100 kilograms reduces fuel consumption by 0.3 liters per 100 kilometers and CO2 emissions by 7.5 grams. By intelligently combining aluminum, carbon fiber-reinforced plastics and new, high-strength steels, manufacturers can achieve further reductions in car body weights.

Differing needs, flexible solutions

Luxurious limousines, small town cars, fast sports cars: every vehicle category has its own price parameters and its own particular priorities. Whereas high-priced cars already integrate various lightweight parts, smaller vehicles still largely rely on conventional solutions. What’s more, not every car has to be lighter in all areas. In terms of the driving characteristics, it is often beneficial for the front or back to be heavier in order to achieve an overall perfect balance. As a consequence, market-ready products are not always about achieving the maximum possible solutions. Depending on specific customer needs and the vehicle category, varying concepts are often required.

Schuler press systems for all manufacturing processes used in lightweight car construction

In the field of lightweight construction, success depends on using the right blend of materials. Each material has its own specific advantages and is correspondingly well suited to differing application fields. Schuler is the world’s only manufacturer to offer technologies and automated press systems for all processes used in lightweight car construction: the cold forming of high-strength steels, e.g. using Schuler’s ServoDirect technology, press hardening with Pressure Controlled Hardening technology (PCH), hydroforming, composites forming and aluminum forming.

Heavy demand for light

Combustion engine, electric drive, fuel cell or maybe hybrid? Nobody is quite sure as yet just how the car industry will develop in future. Nevertheless, or maybe for that very reason, there is strong demand at present for good ideas and intelligent solutions in the field of lightweight car bodies and chassis components. One thing’s for sure though: the future is light. And Schuler is there to ensure that new vehicle concepts can also be put into production.

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