Completed Projects

Aluminum Door

• Advanced engineering program undertaken for Ford Body Engineering
• Aluminium Intensive Vehicle development resulted in 47% mass saving on door in white assembly
• All structural and functional requirements met or exceeded
• Structurally superior to steel door

Multimatic was contracted by Ford to design an all aluminum door system for the Aluminum Intensive Vehicle (AIV) Sable program. Multimatic conducted a comprehensive, computer based design, analysis, and test program and achieved a nearly 50% door-in-white weight saving, and a 30% fully trimmed reduction. The aluminum door system meets or exceeds the functional and structural performance of the steel Sable door, and has been utilized on over 40 prototype AIV Sables.

The basis of the door structure is Multimatic's proprietary dual intrusion beam system that, in conjunction with the inner belt reinforcement, creates a highly rigid triangular spaceframe. All of the members of this spaceframe are aluminum extrusions. The dual intrusion beam system significantly improves the side impact protection and reduces occupant trauma.

A complete manufacturing feasibility study of this aluminum door system was completed on 30 Lincoln Continentals at Wixom Assembly Plant. Some modifications were made to the original concept to improve the manufacturability of the door components and to allow the doors to be processed utilizing current door assembly technology.

A 20 vehicle pilot build of AIV lease Sables was completed by Advanced Vehicle Systems Engineering. These all aluminum Sables, which contain the Multimatic door system, were evaluated for durability and functionality over a 40 month lease period to assess the long term feasibility of extensive aluminum utilization in production.