Maximum weight reduction has been one of Donkervoort’s most important core values for 40 years now. Composites – a product of the continual quest for stronger, lighter and safer vehicle constructions – have played and play a vital role in achieving this. They can potentially reduce car weight by no less than 25%. This reduces fuel consumption for fossil fueled cars by 15% and therefore directly reduces CO2 emissions. Additionally, weight reduction resulting from the use of composites extends the operational range of electric vehicles, stimulating their market uptake, which is an even more sustainable alternative. However, the production of composites is way too expensive for the mainstream automotive industry.
Today, the production of a composite car component of 1 kilogram costs €140 – an average car weighs over a 1,000 kilograms. In recent years, Donkervoort’s in-house Design & Engineering team has developed the patented carbon fiber technology EX-CORE® to enable lighter and stronger car components than ever before. A production process that uses fibers and the EX-CORE foam, which are put in a heated mold to produce composite components in one single shot. The EX-CORE® production process is 10 times more cost effective than traditional production methods. Furthermore, it can produce complex shapes in a single cycle without post-processing. And it uses 33% less energy and no consumables! With the application of EX-CORE®, composites can be produced at the industry’s targeted cost price (maximum €30 per kilogram).