Energy flow through a typical internal combustion engine drivetrain

This chart shows why less than 0.5% of the energy in a typical modern auto’s fuel actually moves the driver, and only 5–6% moves the auto. An auto's weight is responsible for more than two-thirds of the energy needed to move it. All told, 86% of the fuel energy never reaches the wheels.

 

Vehicle retail price and curb weight, new U.S. car sales, model year 2010

Lightweight autos needn’t cost more. The MY 2010 U.S. new-car fleet shows little or no correlation between lighter weight and higher prices.

 

Sales-weighted curb mass and density of new autos sold in U.S., 1986–2009

Autos in the U.S. have increased in weight by 16% since 1986 to an average of 3,533 lb. in 2009. Cars have also gotten denser, rising 14%—from 28 to 32 lb per interior cubic foot. Yet since 1986, U.S. adults got only 8% heavier.

 

Power to accelerate 0–60 mph in 9 seconds

Every 10% decrease in an auto’s weight can raise fuel economy by roughly 6%.

 

Basic characteristics of Revolutionary Plus autos

Our Revolutionary auto class is based on RMI’s extensive work on the Hypercar. We use a cost model for superefficient battery-electric and fuel cell autos for both cars and light trucks. These vehicles, described in this table, are designed to compete with EIA’s average automobile in price and all driver attributes.

 

Industrial grade carbon fiber supply and demand

Carbon fiber material supply is currently increasing by 9–10 million pounds per year. Demand began a 10-fold increase with Boeing’s and Airbus’s new carbon-intensive airplane orders in 2005.

 

Examples of carbon composite structures

The carbon fiber manufacturing market is very concentrated; six companies produce nearly 93% of the world’s supply of carbon fiber.

 

Comparison of carbon fiber vs steel manufacturing costs

Automotive manufacturing costs can be cut by 80% with carbon fiber-based autos vs. steel-based ones due to greatly reduced tooling and simpler assembly and joining. However, such cost savings are currently overshadowed with carbon fiber material prices upwards of $16/lb.

 

Carbon fiber precursor basics

Raw carbon fiber is made from either polyacrylonitrile (PAN) or a petroleum pitch precursor. Rayon was used prior to the development of PAN. These fossil-fuel-based materials come from petroleum refining or natural gas processing.

 

How to make advanced composite hypercar class autobodies

The Hypercar (shown) achieved 53% curb-mass reduction without compromising safety. Its 14-part structure was much simpler than its typical 100–200 part counterparts made of steel and aluminum. A paper by Oak Ridge National Laboratory drafted a concept of a composite intensive body-in-white with 18 parts. Its concept had over a 60% mass reduction, also with uncompromised safety.

 

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