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Aerodynamics
In the past, cars created a great deal of resistance (aerodynamic drag) when they moved through the air.
This was largely due to their large frontal area and high drag. Typical coefficients of drag (CD)
ranged from 0.5 to 0.7. Modern vehicles are much more streamlined allowing air to flow over them with much
less resistance (0.28<CD<0.38) thus decreasing fuel consumption. With a further 20% to 25%
reduction in CD, reducing fuel consumption a further 2% to 2.5% from today’s average should be possible.
Lightweight and Recyclable Materials
Lightweight materials include high strength steel, aluminum, magnesium, titanium, plastics, carbon fibre, and
other composite materials. By using lightweight materials, manufacturers can build more fuel-efficient
vehicles without sacrificing safety, durability and comfort. For every 10% of the weight eliminated from a
vehicle, fuel consumption can be improved by 5% to 7%.
Current aluminum technology can cut half the weight out of a conventional body structure. Many manufacturers
are already using aluminum extensively for complete body structures or selected panels such as hoods, trunk
lids, doors and fenders. Aluminum can also be used in castings that replace cast iron for the engine block,
cylinder heads, transmission housing and intake manifold. Aluminum forgings can be used to replace steel
in the suspension, steering, axles, driveshafts and wheels.
About 75% of the weight of today's mostly metal vehicles is recycled at the end of vehicle life through a
network of vehicle salvage and shredder facilities. This leaves about 25% of the weight of the vehicle,
made up largely of plastics, glass and textiles, that are sent to land fills at a cost to manufacturers and
ultimately to consumer and the environment. New recycling technologies for the plastic content of vehicles show
promise at upping the recyclable total for a vehicle to 95% of its weight. Higher recycling rates will mean
lower vehicle costs and less damage to the environment.
Small Urban Vehicles
In Europe and Asia, small, 2 and 4 passenger vehicles that weigh between 400kg and 900kg and are shorter
than 3.4 meters are commonplace. Because of their compact dimensions, they reduce urban congestion. Because of
their lightweight, fuel consumption in the 3 to 5 litres per 100-kilometer range is achieved.
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