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Extensive, in-depth research studies were undertaken from initial design to the development of vehicle.
These included:
- Occupant packaging study encompassing 3D graphic representations of the occupant compartment with the position of the occupants
- Powertrain layout study of the systems inside the vehicle
- Loadpath definitions identifying the path of maximum stress
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The engineering build team constructed the vehicle through the body in white (BIW) stage when the frame has been joined together, but prior to any chassis sub-assemblies have been integrated into the structure to complete exterior engineering.
Once fully assembled, the prototype was put through precise and rigorous testing using CAE simulations of crash; noise, vibration, and harshness (NVH); as well as thermal and durability load cases.
The body of the vehicle was created using carbon fibre-reinforced plastic (CFRP) which is used in aircraft, automobiles, body armours, and the sports sector owing to their ultra-strong and lightweight characteristics.
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The completed design realised a tub and roof weight of 83kg, a rear frame weight of 60kg and an underbody of 143kg, exceeding JLR’s goal of a lightweight hypercar.
The chassis stiffness desired by JLR was measured three ways – torsion, bending and suspension stiffness. The results of testing achieved an impressive:
- 56 kNm/deg tortional stiffness
- 15kN/mm bending stiffness
- 14-59kN/mm suspension stiffness
