A joint study by Porsche and Alumobility recently reported the steel-heavy roof of the Porsche Taycan electric vehicle (EV) with aluminum could slash its weight by 40%, making the EV lighter without cutting out performance aspects or safety. 

The joint study titled, “Aluminum Lightweight Study: A Conversion of the Porsche Taycan Top Hat from Mixed Material to an Aluminum Design,” was presented regarding its findings at the Car Body Xperience conference in Rochester, Michigan on April 23. The findings of the study revealed that using an all-aluminum top hat structure for the Taycan would not only achieve substantial weight reduction by 40% but will also streamline production by cutting down the number of production parts by around 20%. 

Alumobility Technical Director Mark White expressed the potential avenues based on the results of the joint study stating, “We want to incentivize that jump. If you do an all-aluminum car, you need less parts, less joints and less gauge combinations — which means the cost of manufacturing the car is lower. It’s a big incentive.”

Moreover, the results of the joint study also influenced many decision-makers like Jens Christlein, director of R&D for body-in-white at Porsche, expressing that the study gave “state-of-the-art” technical input on lightweight structures that will inform the company’s decision-making process. 

The joint study further highlights a major innovative discovery of making EVs lighter through material technology, where the concerns to increase efficiency and EV range are associated with weight. With the input of considering aluminum in the EV’s construction material to make it lighter, those concerns can be addressed. 

As EVs are getting more innovative, the joint study spotlights new and interesting approaches that can further the improvements in EV technology that will stand out compared to internal combustion engine (ICE) vehicles. To accelerate the transition into electric mobility, studies that feature innovative research that enhances EV specs will be one of the important components that will further shape a better EV industry.

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