On the Theory of Other Industries Building Cars in the EV Era

Many of you have likely heard the argument that as we enter the EV era, the number of parts will drastically decrease, eliminating the need for existing heavy, large-scale production technology, thereby making it easier for companies from other industries to enter the automotive business.

If this refers to the comprehensive work of development and production for finished vehicles, then this argument is entirely off the mark.

The enormous social risks borne by this industry, coupled with its low profit margins... even a simple calculation reveals how inefficient an investment it is. Unless there is a tremendous demand in the local market, it is unnatural to consider betting on such an industry now, which requires immense effort for little return. Most people on the ground likely feel the same way.

On the other hand, there is no doubt that the era since the 21st century has been changing at an unprecedented pace. It is also true that automobile manufacturers are reaching the limits of maintaining their purity, both financially and in terms of development, to adapt to these changes.

The automotive business, which, due to the number of people involved and the scale of money moving, might appear to outsiders as vested interests, is beginning to explore a direction of aiming for synergistic development through collaboration with other industries.

M and i

BMWWhile "M" offers products that pursue sportiness under BMW's direct control, "i" aims to provide products that pursue sustainability in a similar position.

For the two seemingly opposite entities to be connected under the BMW umbrella, the prerequisite is that they must fulfill the company motto of "Sheer Driving Pleasure." In simpler terms, what brings pleasure to the "i," which anticipates the widespread adoption of electric powertrains?

The full-scale rollout of the "i" brand will likely begin with the "BMW i3," which will premiere at this year's Frankfurt Motor Show. In a technical workshop held prior to this, various answers were prepared in different forms.

A Car Born from the Wind

The venue was the Leipzig plant. Equipped with the latest facilities built after German reunification, BMW's large plant is rapidly preparing for the full-scale production of the i3.

The large wind turbines installed on the premises will eventually number four in total and are expected to become a symbolic presence visible from the Autobahn. Of course, for the i3, they are not just landmarks but also function as a part of its philosophy.

A Different Approach to Car Manufacturing

Naturally, this is also a result of the contribution from the vehicles being manufactured.

BMWThe i3 is constructed with a design philosophy that clearly separates the chassis and body into "drive module" and "life module" respectively, with the former composed almost entirely of aluminum and the latter of carbon.



This means that from the material stage, the engineering is designed to incorporate CO2 reduction with a completely different approach than conventional cars.

For example, in the case of the i3, 50% of the aluminum used in the drive module is made from recycled materials such as aluminum cans.

Carbon That Travels Halfway Around the World

Furthermore, the upper structure, called the "life module," is constructed as a monocoque using carbon material, which has eliminated the need for conventional processes in the production plant.

The body panels are made of polypropylene with directly colored outer panels, reducing water usage in the painting process to almost zero. Additionally, the carbon body, achieved through unique hot molding to attain rigidity and weight comparable to dry carbon while dramatically increasing productivity, eliminates the energy-intensive welding process.



For the i3, being an EV, lightness is an especially crucial point for extending its range.

BMW has long focused on carbon, considered the leading next-generation material for automobiles,BMWand has accumulated know-how in production and quality by using it in the roof panels of some models.

The carbon body production process for the i3, which fully utilizes this expertise, is shaped through a journey that spans more than halfway around the globe.



The reason for this complex mileage traces back to the Landshut plant, which is a hub for BMW's casting technology and has staff and facilities with expertise in molding, making it the core of BMW's carbon processing.

And the fiber processing in the United States has the advantage of being able to cover the vast amount of electricity required for carbon sintering 100% through hydropower from the lake.

Furthermore, the lightness of the material offers the benefit of reduced CO2 emissions associated with transportation. The advanced nature of carbon materials in automotive applications may lie in the fact that even across such long distances, the benefits of hydropower can be fully realized.

The Paradigm Shift Caused by the BMW i3

BMW, whose very name means "Bayerische Motoren Werke" (Bavarian Motor Works), is, needless to say, a manufacturer that has earned global acclaim for the power, efficiency, and sensory appeal of its internal combustion engines.

Looking at the details of the i3, which features an electric motor, it is evident that the company's internal technological development is deeply involved.

On the other hand, it is also clear that for areas such as low-voltage electronics and materials, which are far removed from traditional automotive manufacturers, they have unhesitatingly engaged in technological exchange with external industries.

In any case, it is impossible to move forward without formulating strategies based on completely different concepts than before and inviting knowledge from the right doors. The true difficulty of EVs is likely understood better by automobile manufacturers, who have struggled with them for so long, than by irresponsible outsiders.