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In the past decade, the demand for and development of tailor-welded blanks (TWBs) has increased dramatically. TWBs help reduce body mass, piece count and assembly costs, while potentially reducing overall cost. IBIS Associates, Inc. has performed a cost analysis of tailor welded blank manufacturing through the use of Technical Cost Modeling (TCM), a methodology used to simulate fabrication and assembly processes. IBIS has chosen the automobile door inner panel for comparison of TWBs and conventionally stamped door inners with added reinforcements. Manufacturing costs are broken down by operation for variable costs (material, direct labor, utility), and fixed costs (equipment, tooling, building, overhead labor, maintenance, and cost of capital). Analyses yield information valuable to process selection by comparing cost as a function of manufacturing method, process yield, production volume, and process rate.

The painting of today's automobile incurs both economic as well as environmental costs. Using an approach called Technical Cost Modeling, this paper assesses the cost of painting a steel vehicle using a conventional solventborne painting technique and a UV cure alternative. The UV cure approach is found to have a cost advantage due primarily to decreased material, energy, and investment components. The cost of both systems is examined as a function of changing production volumes (and corresponding production rates) as well as first pass capability, with volume being found to be the more significant contributor. While the UV cure approach needs to be demonstrated at prototype and high volumes, it offers the potential not only for improved cost, but also significantly decreased environmental impact in the form of reduced volatile organic compound (VOC) solvent emissions.