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To both simplify production, and lighten ready-to-
operate/drive vehicle weight, the body should be formed
in a single piece, skratch-proof, 1-2-3 millimeter formed
The production equipment is massively simplyfied, : Just
one wood or aluminium vacuum-forming form shape to
CAD-CAM designed from the styling design model
No mechanical detail components for doors, or window
assemblies, just one entire shell, lifted up for entering
seats, and putting in luggage. (Lifting actuation installed
by simple 'scissors' mechanisms, actuated by air
or electrical linear actuators).
Lightweight : Material density 1.5 - 2.5 grammes/cm3.
Full visibility : Transparant body, no blind angles.
Paint applied for costumization, from the inside, leaving
the outside surface as-is, scratch resistant, and
electrostatically dust-dirt repellant.
processes and tools
sabic. [sirau, Jun 05 2011]
Sheet Forming site.
with opposing twin-mirrored sheets, inside-pressurerized air, as well as outside vakuum could be applied. Possibly to increase productivity, by decreasing cycle's time, and a slightly lower power consumbtion (vacuum can be very expensive to work with). [sirau, Jun 05 2011]
Melting of door fabrics
"The canopy was acting as a magnifying glass and burning a hole in the canopy seal!" [Klaatu, Jun 06 2011]
||No blind angles, except for everywhere the light is distorted by the bent plastic. [-]
||yes, sorry about the spell, : Cars are, by some,
considered as 'clothes' as to what they are seen to
have worn in Society.
||Masking tape, figure patches and pin-striping
techniques will allow the refinement of
||Soluable paint will allow redecorating at intervals.
||The opticals of 'bent' plastic could possibly be
designed to be non-interfeering with normal
perception of views.
||Great link, just the ticket.
||...and when the local pump jockey (if you happen to
live in one of two states where it is illegal to pump
your own petrol) splashes some gasoline onto the
Lexan® and it becomes cloudy or crazed, how much
will it cost to replace? Ask a pilot about Lexan® and
||Ask anyone who lives in a hot climate what happens
to Lexan in a hot Texas sun. [-]
||Industrially applied matarials improve in
performance, and price structure, with wider scale
usage and sales voloume's.
||The 'Lexan' indication is just a current world
reference, for the 'feel' and properties of such a
proposed auto solution.
||I am sure an Industry giant, if it applied it's
research ressource, could find a chemically, and
solar, resistant, long-life spec.
||And, bodies beeing cheep, just a 1-2 year life-span
could be enough, changing the body of you 'new'
car, keeping low-maintenaice EV mechanicals,
according to current and anticipated styling, decor
and fashion trends.
||1. I'm certain 1 mm would be far too thin to
support itself without major warpage. 3 mm
would be as heavy or heavier than steel bodies
due to the need for structural support, both to
support the useless lexan body and to supplant
the now absent unibody strength.
||2. you'd roast underneath it. This is one reason
those 60's pod-type prototype cars with the 1-
piece bubble canopies were never built.
||3. There would still need to be a substantial frame
and chassis, with many mounting hardpoints,
which would essentially ruin the 'look' of your clear
lexan body. Even then, this car would be a flex-
||4. Carbon fiber is superior to lexan in almost every
way save perhaps cost, and is already used.
||//you'd roast underneath it.//
||Maybe, even literally... <linky>
||I like the concept. Instead of plastic make it from glass. Glass cookware is incredibly durable and resistant to elements, if not elephants. Re roasting: treat entire thing as one-way mirror, as some windows currently have. Shatterproofing is already mature technology for windshields. One could own several shells stacked in the garage, swapping out as whim dictates.