An interesting feasibility study entitled Reducing Complexity & Cost through Parts Consolidation was recently commissioned by WorldAutoSteel, the automotive group of the World Steel Association
The organisation says the study’s results demonstrate a credible pathway for manufacturers to rethink how vehicles are designed and manufactured – an intriguing premise that shines a light on the real-world potential of advanced high-strength steels (AHSS).
In the context of automotive design, where we’re used to slight, incremental advances being heralded as enormous success stories, the study’s findings are quite astonishing. Results include a 34% reduction in part count for a front body structure, along with 8% weight savings, 10% reduction in piece cost and the potential for up to US$21 million in overall manufacturing investment savings.
Naturally, Ingo Olschewski, director of WorldAutoSteel, is delighted with the findings. They confirm his belief that, as vehicle architectures evolve for electrification and lightweighting, AHSS are well placed to compete with aluminium and composites in future body structure design. “For high-volume automotive applications, material selection is increasingly driven by the need to balance performance, cost and manufacturability. Our study shows that parts consolidation using AHSS can considerably reduce cost and complexity, while enabling weight reduction,” he explains.
“Technologies such as third-generation AHSS and tailor-welded blanks allow multiple grades and thicknesses to be combined within a single part, optimising strength and formability locally. Together, this enables a weight reduction of 8% in the front body structure, while maintaining safety and performance,” Olschewski details.
CONSOLIDATION STRATEGY
But successful parts consolidation – particularly across mixed-material architectures – isn’t always straightforward, and Olschewski acknowledges there are several challenges to be addressed. “In the automotive industry, pressures have never been greater to find ways to deliver more efficient and cost-effective manufacturing solutions that don’t compromise vehicle performance or safety. This is especially relevant for battery-electric vehicle (BEV) platforms that incorporate a wide range of structural components,” he comments.
“These barriers for BEVs formed the basis of our study, which focused on parts consolidation for a steel front vehicle body structure. The potential for a 34% reduction in part count combined with 10% piece-cost savings demonstrates a clear opportunity to reduce complexity and costs,” says the steel evangelist.
Discussing mixed-material architectures, Olschewski notes that consolidating components can introduce a range of systems-engineering challenges in vehicle manufacturing – affecting factors such as cost, scalability, safety and crash performance. “For example, joining mixed materials can create corrosion issues, while crash performance can be impacted by different material stiffness or stress,” he explains. WorldAutoSteel’s report highlights the role of tailor welded blanks, AHSS and advanced stamping simulation in overcoming such challenges and enabling parts consolidation.
Looking ahead to the next generation of BEVs, where does Olschewski see the biggest remaining limitations in pushing consolidation even further? “Next-generation BEV platforms are pushing towards higher levels of functional integration through structural battery packs and integrated systems. As architectures evolve, manufacturers must balance increasing integration with serviceability, cost efficiency and production feasibility,” he states.
“One of those remaining limitations is repairability. Highly consolidated structures can result in larger repair zones, higher replacement costs and longer repair cycles. Steel offers opportunities to improve this through modular, replaceable structures and excellent weldability, helping to reduce repair complexity and insurance costs.”
And, he adds, “From a broader perspective, material decisions are increasingly assessed through a lifecycle lens, where steel also offers advantages in terms of lower production emissions and high recyclability.”
RISK VERSUS REWARD
As vehicle platforms become more modular and EV-focused, there’s another issue around parts consolidation that will require greater focus: assessing when parts consolidation creates true system-level value versus introducing downstream risks in repairability, tooling complexity or supply chain flexibility. On this subject, Olschewski observes: “The challenge is not just making fewer parts, but ensuring the overall vehicle structure still delivers on its key attributes – including cost, safety, manufacturability and scale.
“Our study findings demonstrate that minor adjustments to material grade and strength enable a reduction in the total number of stamped parts, which helps streamline the assembly process, requiring fewer machines, tools and less overall factory space. It also reduces production complexity, resulting in an estimated manufacturing investment cost savings of US$21 million. Crucially, this work underlines a scalable pathway that leverages existing manufacturing infrastructure, helping to minimise disruption to production,” he emphasises.
CONCEPT CAR
For its study, WorldAutoSteel tasked Ricardo, a global specialist in automotive technology development, with creating a virtual solution for a new front body structure using the Steel E-Motive vehicle concept as the baseline reference.
Using the Steel E-Motive vehicle concept as the base, the new design achieved a reduction of 13 parts – 34% of the overall. The reductions were based on consolidating individual parts into larger single hot and cold stamped parts, often incorporating more complex geometry. “The study highlights the applicability of this solution for real-world use in current and future vehicle platforms,” comments Olschewski.
