Niche Vehicle Network

Niche Vehicle Network

The Challenge:

A passenger car manufacturer was looking for significant mass reduction within the exhaust system. The objective was to reduce the mass by 50% and be commercially viable via a structured collaborative R&D project approach. A reduction in weight would also provide improved driving dynamics and fuel efficiency whilst reducing carbon emissions.

These outcomes were to be obtained by:

  • Using lighter/thinner gauge alternative materials
  • Reducing part count and number of joints
  • Improving heat shield provision at the same time as reducing weight
  • Developing lighter weight joint solutions


The Impact:

AML fleet savings on 400 cars (10%):

  • Fuel saving, 50,000 litres (£60k)
  • CO2 saving, 127 tons (1.3g/Km per car)
  • 128g/Km > 95g/Km (4% of the solution)
  • Material saving, 5,640Kg (14.1Kg per car) (1% vehicle mass)

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