Magna develops ultralight door module

Detroit-based automotive supplier Magna Intl. Inc., in cooperation with the U.S. DOE and partners FCA US and Grupo Antolin, has developed a new, ultralight door architecture that achieves the project objective of 42.5 percent mass savings compared to an average current production door.

The door was developed in less than 10 months while keeping the cost within accepted industry parameters and providing a product that applies to approximately 70 percent of the light-vehicle market.

A key innovation associated with the development of the ultralight door includes integration of Magna's SmartLatch™ electronic latch system, the company reports. This eliminated the need for mechanical hardware and enabled the development of a carrier module with integrated glass guides and lift capability of a lightweight hybrid glass laminate—an industry first.

The door-in-white assembly makes extensive use of aluminum, which achieves about half of the total mass reduction of the door assembly. Overall, the project employs readily available materials that can be made using existing manufacturing processes, without a significant increase in production costs or changes in body-shop infrastructure, according to the company.

The application of advanced molding technologies and polymers contributed about 7 percent to the total mass reduction.