By Melissa Reynolds

Ferrari sees lighter cars as the best way to reach its goal of increasing fuel economy 40 percent and reducing emissions 25 percent without compromising its reputation for performance.

A new lighter-weight car frame may be the answer to both reducing some greenhouse gas emissions and saving Europe's ailing auto industry.

The SuperLight Car Research and Development Project is co-funded by the European Commission under the 6th Framework Programme involving 38 leading organizations from nine European countries. Behind SuperLight Car is a group of seven European car makers, including Volkswagen (coordinator), Fiat Research Centre, Opel, Renault, Volvo Technology Centre, Porsche and Daimler, all working together to bring lightweight car technology to the masses, while reducing car weight by 30%.

The new SuperLight Car, which was unveiled earlier this year in Germany, has a lightweight frame using a variety of materials, design and manufacturing techniques. Its goal was to develop concepts that would allow the 30% weight reduction in the frame, while still keeping within the cost range for manufacturing, using Volkswagen's Golf V model as an example of the compact class passenger car.

With European car manufacturers restructuring their operations to meet new concerns over climate change and laws requiring fewer greenhouse gas emissions, the SuperLight Car could not have come at a better time.

Because about one-third of a passenger car's total fuel consumption depends on its weight, and car weights have risen in years, greenhouse gas emissions can be reduced by reducing a car's weight and can save millions of tonnes of fuel and carbon dioxide.

The final product was a success, weighing in at 171kg which represents a 39% reduction in weight, while using new materials that did not increase production costs. Light alloy hot forming aluminum and magnesium were used for the frame's external panels, hot formed steel for the door apertures, fibre-reinforced thermoplastics for the roof cross beam and rear floor, cast aluminum for the rear longitudinal strut, and reinforced polymer for the seat cross member. The steel parts made up 50% of the frame's weight, aluminum 35%, magnesium 8% and plastic 7%.

All of these materials were used while still meeting automotive requirements for stiffness, crash performance, fatigue and corrosion resistance, and other performance requirements.

With such a model pointing the way for car manufacturers to reduce greenhouse gas emissions, it is hopeful that such a plan will soon be used by car makers everywhere.