Advanced high-strength steels (AHSS) can play a significant role in helping vehicle manufacturers (OEMs) simplify complex vehicle architectures, unlock substantial cost savings and maintain performance and safety standards, according to a new steel industry feasibility study commissioned by WorldAutoSteel
As OEMs face increasing pressure to streamline vehicle design, particularly for battery electric vehicle (BEV) platforms, the feasibility of parts consolidation at scale is no longer a question. WorldAutoSteel’s latest study, conducted in collaboration with Ricardo, a global specialist in automotive technology development, provides practical answers to this industry challenge. Using a virtual front body structure based on the Steel E-Motive vehicle concept, the study shows how greater use of AHSS combined with modest assembly line changes, can deliver measurable reductions in part count, weight and manufacturing investment.
How can OEMs reduce front body structure part count?
The study found that front body structure part count can be reduced by up to 34 percent. Starting from a baseline of 38 components, the redesigned structure achieved a reduction of 13 parts, bringing the total down to 25.
This was achieved by consolidating multiple individual components into larger single hot and cold stamped parts, often incorporating more complex geometry. The consolidation approach simplifies tooling and assembly fixtures while retaining manufacturability.
What weight and piece cost savings are possible?
In addition to reducing part count, the study identified an eight per cent weight saving and a 10 per cent reduction in piece cost for the front body structure.
These savings were realised through the use of advanced high-strength steels that offer high strength and formability, supporting the production of larger, more integrated components without loss of structural performance.
Does parts consolidation affect safety or ease of repair?
Structural performance was maintained in the consolidated design. The study found no differences anticipated in terms of ease of repair compared with the original architecture.
High strength and formability were achieved using hot stamped press hardened steel. The study also indicated that further improvements in cost and weight could be achieved through the incorporation of tailor welded blanks into consolidated parts.
How much manufacturing investment can be saved?
It is estimated that a $21m reduction in total manufacturing investment costs could be achieved for the front body structure through simplified tooling and assembly fixtures.
If a similar consolidation approach were applied across the complete body-in-white and closures, the total reduction in manufacturing investment could be in the order of $112m, when considering buildings, assembly equipment and tooling costs.
Why AHSS supports scalable vehicle design
WorldAutoSteel, the automotive group of the World Steel Association, commissioned the study as part of its ongoing work to support the automotive industry with practical engineering tools and research programmes. Its members include 17 of the world’s largest automotive steel producers.
Commenting on the findings, Ingo Olschewski, Director, WorldAutoSteel, said the study demonstrates the potential of AHSS to address key challenges facing next-generation vehicle architectures. He highlighted steel as a sustainable, safe and scalable structural material that supports parts consolidation, assembly line efficiency and cost efficiency as well as high-performance engineering solutions.