Alumobility and Porsche Conduct Aluminum Lightweighting Study

May 3, 2024

Alumobility, the global association committed to advancing the adoption of aluminum in the automotive industry, has collaborated with Porsche on a new study entitled, “Aluminum Lightweight Study: A Conversion of the Porsche Taycan Top Hat from Mixed Material to an Aluminum Design.” Alumobility technical director Mark White and Porsche’s Jens Christlein, director R&D body in white, presented the scope of the study and its results during the Automotive Circle’s Car Body Xperience’s electrification program, held April 23rd in Rochester, MI.

The theoretical case study focused on converting the existing steel-intensive mixed-material body top-hat structure of the Porsche Taycan to an all-aluminum top hat. The result: an approximated 40% weight savings, while maintaining attributes for safety, body stiffness and performance. The project further demonstrated that aluminum-intensive vehicles offer manufacturing-efficiency opportunities by reducing the number of parts, joint types and total joint count. In addition, it was determined recycled aluminum would lower lifetime emissions compared to the steel reference.

“For Porsche it is a great benefit to get state-of-the art technical industry input regarding lightweight structures,” said Christlein. 

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