Affordable Vehicle Lightweighting

Ricardo is updating its Vehicle Mass Manager tool with new capabilities as part of the Horizon 2020 ALLIANCE project addressing the increasing need for fuel/energy efficiency in both conventional and electric vehicles though effective and affordable light weighting methodologies.



ALLIANCE is a Horizon 2020 project which seeks to address the increasing need for fuel/energy efficiency in both conventional and electric vehicles though effective and affordable lightweighting methodologies.

The main objective of the ALLIANCE are to enable to reduction of energy consumption by 10% and GWP by 6%, compared to a conventional vehicle.

Customer Benefit

Vehicle mass reduction is a proven method to achieve vehicle efficiency improvements and reduce CO2 and emissions. Engineers are faced with numerous complexities when undertaking mass reduction of a passenger car vehicle; namely, vehicles typically have 3000 to 7000 parts or modules each, and overall vehicle mass reduction is achieved by reducing the weight of several components.

Numerous solutions, approaches, and technologies are available to engineers to reduce the weight of vehicle components and modules with each solution having different potential cost, GWP, and performance effects. The light weighting solutions are often demonstrated or are
in production on a single vehicle type/segment, therefore additional efforts are required to envisage and realise the effect of the solution on other vehicles.

Ricardo’s Mass Manager tool and the enhancements incorporated through the ALLIANCE project enable engineers to achieve complete vehicle mass reductions in a much quicker timeframe and more robustly than conventional methods.


Ricardo’s Vehicle Mass Manager software tool has undergone enhancement and improvement within the ALLIANCE project. A new “Use Case Database” has been added, enabling light weighting technologies to be stored/saved within Mass Manager. The database contains the light weighting technologies as developed by the ALLIANCE project partners.

The user can apply these technologies to a complete vehicle and assess the mass, cost, GWP and performance impact. Additionally, a scalability function is provided, enabling a single light weighting technology and its parameters to be scaled from its native/parent vehicle to another vehicle.

The scaling is based on a statistical trendline which is obtained from a data sample of other benchmark vehicle data. A transferability function has also been developed, enabling the mass reduction, cost, and GWP parameters from one “source” lightweight part to be transferred to another “target/
candidate” part, again based on a statistical function derived from component benchmark data.


This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement no. 723893