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An experimental vehicle designed to minimise total cost of vehicle ownership has been developed. The uncertainty of future energy prices dictated that whole life energy consumption should be conserved. The design objectives demanded significant improvement in fuel economy without adversely affecting performance, ride, handling, interior noise, vibration, safety, emissions or accommodation when compared with existing medium sized European Cars. These objectives were met by utilizing lightweight corrosion resistant materials and structural bonding together with reduced drag and improved power train efficiency. The body structure is manufactured from adhesively bonded sheet aluminum alloys.

Following-earlier work on the development of a concept car for the nineties employing a weld-bonded aluminum alloy load bearing base unit, work has continued on this aluminum structured vehicle technology (ASVT) to develop and test the manufacturing feasibility and economics for high volume production. The paper reviews the feasibility of the total manufacturing process highlighting experiences from further work, including developments in aluminum welding technology. The overall economic cost comparison between an aluminum structured vehicle (ASV) and a spot-welded coated steel monocoque vehicle shows that there need not be a cost premium for the aluminum structured car.