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LIGHTWEIGHT

RLE International has many years of experience and was able to achieve great cost efficiency for several platforms due to modular concepts. Besides, we are highly competent for an "intelligent lightweight design of the body in white" because of an extensive expertise in hybrid aluminum design. 

E-SUV Project

RLE partnered with Henkel to evaluate the potential of lightweight and safety concepts combining Henkel's material science solutions together with RLE's Engineering expertise.

  • Proof of concept of new structural solutions

  • incorporate structural inserts & adhesives to achieve significant weight reduction by:

    • Substrate change to light metals​

    • material downgauging

    • topology optimization

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Vaulted Aluminum Structural Panels

RLE developed a vaulted aluminum panel that was to replace the rear bulkhead, previously made of steel.

  • The rear bulkhead panel ties the upper and lower rear cross-members together, and provides torsional strength to the rear structure.

    • increase in stiffness through vault structure​, leading to savings in material and weight

    • Tool-less structuring through pressure and self-organization of the vaults, subsequent pressing with simple tool

    • Excellent NVH behavior

    • Excellent crash properties through increased energy absorption

Retractable Hard Tops (RHT)

RLE provided a customer with concept information regarding materials, production methods and mass for an alloy intesive RHT structure.

Vehicles with RHTs are often associated with significant mass increases over a coupe equivalent. Not only is the RHT mechanism itself heavy, structural BIW reinforcements add further mass to the vehicle over a coupe equivalent.​

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