Good simulation has eliminated metal from the part in the forfour vehicle being launched tomorrow

Good simulation has eliminated metal from the part in the forfour vehicle being launched tomorrow

The new Smart forfour vehicle, to be launched in Germany tomorrow, has made a breakthrough in automotive design with an almost all-plastic front-end module. Smart had originally intended to use a hybrid plastic-metal design. But Alexander Pothoven, a bodywork group leader at Smart, told PRW.com: “We started with the hybrid idea, but good simulation work meant that we have found it possible to throw out metal.”

Pothoven said the benefits of a plastic design included a 30% lower investment cost, more than 10% weight saving, simpler production, and no need for corrosion protection. The single all-plastic moulding, made in 40% glass fibre reinforced PP, replaces what would have been a hybrid design comprising 110 parts.

The Smart forfour has arisen through the new compact car (NCC) project between Smart, Nedcar and Mitsubishi in Born, The Netherlands. The Mitsubishi New Colt shares 40% of the parts with the forfour and is due for retail launch in May. The subsequent CZ3 model is already at the concept stage.