Mario Greco

    

Director, Strategy & Marketing, Global Automotive 
Novelis Inc.
 View Biography
    

    

Nando Tedeschi

    

Director, Business Development, Global Automotive 
Novelis Inc.
 View Biography
    

Cost Effective Solutions in Aluminum Roll Forming for Body Structure and EV Systems

The pursuit of mass reduction in vehicle body structure design is crucial for improving efficiency, performance, and cost-effectiveness. Engineers have explored various vehicle architectures and manufacturing technologies, leading to advancements in materials and product innovations. With the rise of electrification and the added mass from battery packs and consumer demand for luxury features, OEMs face new challenges in maintaining crashworthiness and cost-effective mass reduction.

Research indicates that a 10% weight reduction can reduce fuel consumption by 6%-7% with engine downsizing or by 4%-5% without downsizing, making weight reduction a key goal.

As electric vehicles are expected to represent over 40% of sales by 2030, OEMs must meet evolving crash and safety requirements.

The automobile industry has evolved over the past three decades, introducing aluminum-intensive structures, advanced press-hardened steels, and carbon fiber composites into vehicle manufacturing. Tesla's introduction of ultra-large die casting has further advanced body structure complexity.

Roll forming technology, which has existed since the 1800s in the architectural and roofing industry, is now being applied to automobile parts to meet safety requirements. However, as electrification becomes more prominent, complex aluminum extrusions are used to reduce crash deformation and reinforce body areas.

Aluminum roll forming with high-strength materials is seen as an opportunity to lower vehicle body costs while maintaining lightweight benefits and enhancing structural performance. Companies like Novelis are developing advanced automotive-grade alloys for roll-formed sections, significantly improving stiffness, crash performance, and cost-effectiveness.

Primary Takeaways:

• Mass reduction remains a critical focus in vehicle design, driven by the pursuit of efficiency and performance. Reducing weight by even 10% can yield substantial fuel consumption improvements.
• Electrification is changing the automotive landscape, with OEMs facing the challenge of meeting evolving crash and safety standards while managing added mass from battery packs and consumer demands for luxury features.
• The automotive industry has evolved from traditional steel unibody construction to complex multi-material architectures, including aluminum-intensive structures and advanced composites.
• Aluminum roll forming with high-strength materials is emerging as a cost-effective solution to enhance structural performance, lower costs, and maintain the benefits of lightweight design in vehicle body structures. Companies like Novelis are at the forefront of developing advanced alloys for this purpose.

    

    

Tom Alongi

Partner 
UHY LLP
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Dan Bruce

Principal 
UHY LLP
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Strategies for Metalformers to Cash In on EV Opportunities

An electric future seems inevitable. Do you have a strategic plan? Find out where metalformers can cash in on EV opportunities and position themselves for success in the future.

    

    

Steve Horaney

VP 
Sales and Membership, MEMA
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Michael Haughey

President & CEO 
North American Stamping Group, LLC
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Donna Kuhr

CEO/President/Managing Partner 
PTM Corporation
 View Biography

Roundtable Discussion:
The Ever-Evolving Automotive Supply Chain

In this era of electrification and supply-chain issues, collaboration and innovation are key. Hear how suppliers can work hand-in-hand with the OEMs, to best position themselves in today’s automotive industry.

    

    

Kellie Lindsay

    

Director of Strategic Partnerships 
Autotech Ventures
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External Innovation and Venture

Kellie will discuss how leading tier suppliers are leveraging external innovation through venture. She’ll also discuss trends in venture startups in the automotive and ground transportation sector and opportunities for Tier Two and Tier Three suppliers.

    

    

Dan Sharkey

    

Partner 
Brooks Wilkins Sharkey & Turco PLLC
 View Biography
    

A Legal Discussion with Dan Sharkey

Dan will update participants regarding the various legal challenges they face, then will answer questions on legal issues affecting them upstream with their customers and downstream with their suppliers: contracts, warranties, tariffs, strikes, recalls, NDAs, payment debits—you name it. Consider this a chance to bring your issues to an industry-leading lawyer with 25 years of experience and a unique understanding of the issues facing automotive suppliers.

    

    

Alex Chapman

    

President 
Ridge Creek Global
 View Biography
    

Opportunities for Metalforming in the Energy Transition: From Renewable Energy and Batteries to Electrolyzers, EVs, Fuels Cells and More

Alex will discuss opportunities for metalforming in the energy transition from a macro perspective to industry-specific opportunities.

• The demand for carbon-neutral solutions, scaling of technology and geopolitics have changed the narrative of energy markets and the energy transition.
• The reshoring and incentives in the Inflation Reduction Act have turbocharged the opportunity for manufacturing of key technologies for the energy transition in the United States (solar panels, batteries, EVs, fuel cells, electrolyzers) and the companies and parts involved.
• The opportunity for the metalforming industry in the energy transition. Companies that are involved in batteries, fuel cells and renewables not only will position themselves as industries leaders in the electrification of the automobile industry, but also benefit from the fact that those technologies have electrical grid applications.