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During the past years advances in fuel efficiency of car engines did not result in the expected reduction in overall fuel consumption of new car generations. One reason is the increasing vehicle weight. In an overall–weight analysis of an automobile the engine and as part of it, the crankcase represents a single component with a high weight reduction potential. This paper discusses weight reduction strategies using lightweight materials and modern design approaches. The application of lightweight materials for new crankcase concepts implies comprehensive design considerations to achieve weight reductions as close as possible to the potential of the selected material. A specific approach for inline and V–engine crankcase concepts is discussed in detail. Engine weight reduction can also be achieved through substituting large and therefore heavy engines with small high performance engines.

The demand for improved fuel economy and the request for Zero Emission within cities require complex powertrains with an increasing level of electrification already in a short-termed timeframe until 2025. According to general expectations the demand for Mild-Hybrid powertrains will increase significantly within a broad range of implementation through all vehicle classes as well as on electric vehicles with integrated Range Extender (RE) mainly for use in urban areas. Whereas Mild Hybrid Vehicles basically use downsized combustion engines at current technology level, vehicles with a high level of powertrain electrification allow significantly different internal combustion engine (ICE) concepts. At AVL, various engine concepts have been investigated and evaluated with respect to the key criteria for a Range Extender application. A Wankel rotary engine concept as well as an inline 2 cylinder gasoline engine turned out to be most promising.