A hybrid structural assembly for a motor vehicle includes a casting and a structural inlay. The casting includes a plurality of structural components joined together in a casting process to form structural load paths and extending in a plurality of directions in a 3D space. The casting includes a cast-allowable alloy material. The structural inlay is secured to at least one of the structural components. The structural inlay includes a material having at least one of a higher ductility and a higher toughness than the cast-allowable alloy material.

A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.

The invention relates to a frame, comprising, on each of its two sides relative to a vertical longitudinal center plane of the roof, a respective longitudinal beam made of sheet metal and at least one transverse beam made of sheet metal and connecting the two longitudinal beams to each other. The longitudinal beams and the at least one transverse beam are connected to each other via joint lines made of polyurethane foam. Moreover, a method for producing the frame is proposed.

A manufacturing system may include at least one clamp configured to maintain a distance of separation between a first component and a second component for an epoxy provided therebetween. The manufacturing system may also include a laser, and a controller in communication with the laser. The controller may be configured to cause the laser to direct at least one light beam against one of the first and second components to heat the epoxy by conduction to a cure temperature.

Manufacturing cell based vehicle manufacturing systems and methods for a wide variety of vehicles are disclosed. In one aspect, a manufacturing cell configured for assembling a frame of a vehicle is disclosed. The manufacturing cell includes a positioner, a robot carrier and a robot. The positioner is configured to receive a fixture table configured to hold the frame. The robot carrier includes a vertical lift. The robot is configured to assemble the frame. The positioner is configured to support the frame in a vertical position during an assembling process. In another aspect of the disclosure, a system for manufacturing a vehicle based on a manufacturing cell is disclosed. In another aspect of the disclosure, a method for manufacturing a vehicle based on a manufacturing cell is disclosed.

Provided is a vehicle body side structure to reduce a center pillar in weight and suitably prevent deformation of the center pillar and separation of a stiffener from a roof side rail due to a side collision load. The vehicle body side structure includes a stiffener having a stiffener upper part provided above a central part in a height direction of a center pillar. The upper end of the stiffener upper part is joined to a roof side rail from an outer side in the vehicle width direction. The stiffener upper part has a trough extending in the vertical direction of the vehicle and recessed inward in the vehicle width direction. The trough 81d is recessed deeper as coming closer to a central part in the vertical direction of the stiffener upper part from the upper end and a lower end of the stiffener upper part.

A chassis platform module for an electric vehicle may include: a main frame having a battery mounted thereon; and a front wheel-side support frame unit connected to a front of the main frame. The front wheel-side support frame unit may include: a pair of first support frames disposed in a width direction of a vehicle, and each having a first connection groove formed at a front end thereof; a pair of second support frames disposed at a front of the pair of first support frames, respectively, and each having a second connection groove formed at a rear end thereof; a connection frame having connection protrusions inserted into the first and second connection grooves, respectively; an adhesive part adhered to the inner circumferential surfaces of the first and second connection grooves; and a fastening member coupled to each of the connection protrusions through each of the first and second support frames.

A cover module of a charging port for an electric vehicle includes a panel coupling body comprising a charging housing fixed to an inner panel of a vehicle body of the electric vehicle to form a mounting hole, and a side outer coupled to face the inner panel fixed to the charging housing so that the mounting hole formed by the charging housing and the inner panel is maintained, and a cover main body formed in a shape corresponding to the mounting hole, provided with a plurality of hooks along an edge thereof to cover the mounting hole, and coupled to the panel coupling body by the hooks.

A pickup truck box assembly includes a pair of longitudinal frame rails, an extruded cross-member, and a truck bed. The cross-member has a uniform longitudinal cross-section assembled perpendicular to the rails and defines a rectilinear profile with a front flange extending from a cross-member upper portion on a front side and a rear flange extending from the upper portion on a rear side. The truck bed is secured on top of the flanges and the cross-member upper portion. The cross-member may include a first end adjacent a first wheel well defined by the truck bed and a second end adjacent a second wheel well defined by the truck bed such that the cross-member spans between the wheel wells. The ends may be spaced from their respective wheel wells a distance selected to provide space for a truck box inner panel.

A body structure for a passenger car has B-pillar reinforcements of which each have an upper attachment section for attachment to the roof area and a lower attachment section for attachment to the floor assembly or to a side sill. The B-pillar reinforcements are formed as integral tubes made of high-strength steel material and, between the lower attachment sections of the tubes and the upper attachment sections thereof, have a curved course having a constant radius of curvature.