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28.11.2013
Red, yellow and green – everyone is familiar with traffic light colors and what they represent.
Naturally, not all cars will have all of these symbols, and they may even have ones different from those shown here. From EDAG: A special space frame structure covered with the type of lightweight plastic outer skin panels and already produced by EDAG as Class A-type "HT PU RIM components" for low-volume series, has been developed for the EDAG "Light Car - Open Source.
High-strength, thin-walled aluminium structural cast parts produced by Honsel, light metal processing specialists, were used for the structural nodes at the rear and in the B-column of the EDAG "Light Car - Open Source". Meanwhile, in your car, the appearance of twinkling lights can sometimes be quite mystifying. With a minimum of capital expenditure and using polyurethane technology, it is possible to bring about weight-optimised exterior skin components that can be used economically in low-volume series, while providing a high degree of design freedom.The Gaia battery with lithium iron phosphate cells has been integrated in the main floor of the platform, and is part of the load bearing structure.
Numerous extruded sections, some of them in innovative multi-chamber designs, were also used by our open source partner Honsel. The symbols on the signal lamps in the cockpit are standardized, but not always very “illuminating.” Some of the symbols are different in North America, or they are labeled in English. One technical highlight is the demonstration of the aluminium node formed using heat and a gaseous medium.
By keeping themselves constantly geared to the potential of an electric drive system, EDAG engineers designing the package have achieved a wheelbase measuring 2.90 metres.


On account of the high specific degrees of strength and rigidity, and also the enormous amount of energy needing to be absorbed in the event of a collision, the front panel and boot lid were represented in organo sheet (endless fibre reinforced thermoplastic synthetics). However, the blue light for the high beams plays a special role, as does the red symbol for the hazard lights, which originates from the time when you were only permitted to use the hazard lights when your car broke down. These semi-finished fibre composite products are geared to requirements, and can be reshaped using simple pressing technology in very short cycle times.
This guarantees not only adequate energy absorption by crash-relevant structure components, but also maximum stability at the lowest possible weight, and the best possible protection for passengers and the battery in the event of a collision. In this way, low-cost, three-dimensional components become possible, even where large quantities are concerned. To this end, laser-welded and partially hardened sections made of extremely high performance steel were used in the floor, door sill, A-pillar and front end areas.
This technology was contributed by our open source partner Bond-Laminates.The need for thin-walled cast steel body components was met through the involvement of our open source partner, CX-Gruppe, a company specialising in casting technology. Developed by our open source partner Linde + Wiemann, this process makes it possible with precise accuracy to increase the strength and expansion properties of the component in areas where particular demands are made on material strength. The exemplary application of thin-walled, high-strength cast steel spans the front structural nodes, floor, door sill and the integral suspension strut domes.
In this way, optimal solutions can be applied to vehicle and component characteristics, production costs and weight.


This means that it might soon be possible to make ribbed and topologically optimised cast parts in high-performance body structures out of steel, something which was previously limited to aluminium cast parts.
Linde + Wiemann also displayed a section with a complex contour and varying cross section, which featured a continuous weld made using the ATEC form fixture process.
This process works in much the same way as hydroforming, albeit with a gaseous medium and the application of temperable high-strength steel, as press-hardened components do. In order to be able to join together the various materials used in the EDAG "Light Car - Open Source", a special mechanical joining process was called for, in addition to traditional welding. High-speed bolting with the RIVTAC®, a hand-held device, is the ideal way of joining aluminium, steel and fibre composites, and even hybrids. Parts can be joined together at an amazing speed, without any need for punching holes beforehand.
The process is ideal for joints on bend-proof flanges and for closed sections which can be found numerous areas in the space frame structure of the EDAG "Light Car - Open Source".



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