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Nemak showcases an innovative front car body concept and an innovative modular battery structure

Nemak proves itself as a leading supplier of innovative lightweighting solutions for the automotive industry with a newly developed front car body concept, unveiled at the EUROGUSS show in Nuremberg, Germany. The design integration into existing surrounding and concepts on the one hand, and crash structure concept considering the entire body structure on the other, are main benefits of the solution.

The presented innovation is proof of how to engineer integrated solutions for the customer based on Nemak’s capabilities in research and development and its deep expertise regarding materials design and manufacturing technologies. The engineering team is based in Germany and Poland as part of the vehicle structures organisation. Several materials are united with an innovative combination of manufacturing technologies – using solutions in casting, sheet metal forming and extrusion – assembly and joining technologies (thermal and non-thermal) are also combined. The demonstrator proves both with showing the advanced concept for an A-pillar. ?

With the front car body concept developed by Nemak, the following key benefits are realised:

  • Design integration into existing surroundings and concepts.
  • Crash structure concept considering entire body structure.
  • Highest flexibility by exchanging components.
  • Functional integrity.

Nemak presented the newly developed front car body concept together with other innovations at EUROGUSS in January.

The concept has an innovative lightweight battery structure for full electric performance vehicles. It is engineered for modular platforms of full electric vehicles. The multi-material design using aluminium, steel, magnesium and composites ensures that the right material is used on the right location. This, along with the multi-process solution, guarantees a maximum of crashworthiness and the concept features required cell volume with a target range of 330km and 60kWh.

Considering the market needs for lightweighting with regards to battery electric vehicles, Nemak developed an innovative modular battery structure concept which was presented for the first time at the show in Nuremberg, Germany. The concept demonstrates the company’s capabilities in using manufacturing technologies in combination with thermal and non-thermal joining technologies to integrate different types of material into the component. The unique battery housing concept guarantees a safety environment, for example with an underbody impact protection on the one hand and on the other hand by a functional integrated thermal management solution.

Another highlight of the concept is the maximum crashworthiness of the construction from a lightweight perspective with its load cases (pole crash test, bollard test and underbody impact test).

Nemak is a leading provider of innovative lightweighting solutions for the global automotive industry, specialising in the development and manufacturing of aluminium components for powertrain and body structure applications. The company employs more than 23,000 people at 38 facilities worldwide, generating annual revenues of US$4.3 billion in 2016.