Abstract: A battery box for an electric vehicle includes an Al casting that extends between and joins to a BIW or chassis rails of the electric vehicle. The Al casting includes a bottom wall, a side wall with a pair of rails that are securely attached to the BIW or chassis rails of the vehicle, and a plurality of cross members. The bottom wall, the side wall, and the plurality of cross members define a structural enclosure with a plurality of battery compartments and at least one crush zone, and the structural enclosure is load bearing member of the electric vehicle.

Abstract: A vehicle roof structure of a vehicle includes an outer roof panel and a single, unitized inner roof panel. The inner roof panel is separate from the outer roof panel and is secured to the outer roof panel. The inner roof panel includes a plurality of roof headers, a roof bow, and support braces. The roof headers are spaced apart from each other and extend in a transverse direction relative to a longitudinal direction of the vehicle. The roof bow is spaced apart from and positioned between two roof headers of the plurality of roof headers and extends in the transverse direction. Each support brace is positioned between the roof bow and one of the two roof headers. The support braces extend from the roof bow to the one of the two roof headers and extend in multiple directions.

Abstract: A roof rack assembly for a vehicle includes a pedestal including an indentation. A roof rail is movable between a first configuration and a second configuration relative to the pedestal. In the first configuration, a toggle loop of the roof rail is positioned in a first orientation relative to the indentation. In the second configuration, the toggle loop is positioned in a second orientation relative to the indentation.

Abstract: A sun visor assembly for a vehicle that includes a mount configured to be connected to the vehicle. A guide rod having a first portion that includes a head and a second portion with a terminal end is operably coupled to the mount via the head. An impact point is at the terminal end of the second portion. The guide rod and the impact point are configured for use as a window breaker tool in a disassembled position. A visor is operably coupled to the guide rod in an assembled position and is rotatable about the guide rod from a first position to a second position. The visor includes a channel defined within the visor that is configured to receive the guide rod.

Abstract: A roof rack assembly for a vehicle includes a pedestal including an indentation. A roof rail is movable between a first configuration and a second configuration relative to the pedestal. In the first configuration, a toggle loop of the roof rail is positioned in a first orientation relative to the indentation. In the second configuration, the toggle loop is positioned in a second orientation relative to the indentation.

Abstract: A roof rack assembly for a vehicle includes a pedestal including an indentation. A roof rail is movable between a first configuration and a second configuration relative to the pedestal. In the first configuration, a toggle loop of the roof rail is positioned in a first orientation relative to the indentation. In the second configuration, the toggle loop is positioned in a second orientation relative to the indentation.

Abstract: A sun visor assembly for a vehicle that includes a mount configured to be connected to the vehicle. A guide rod having a first portion that includes a head and a second portion with a terminal end is operably coupled to the mount via the head. An impact point is at the terminal end of the second portion. The guide rod and the impact point are configured for use as a window breaker tool in a disassembled position. A visor is operably coupled to the guide rod in an assembled position and is rotatable about the guide rod from a first position to a second position. The visor includes a channel defined within the visor that is configured to receive the guide rod.

Abstract: A battery box for an electric vehicle includes an Al casting that extends between and joins to a BIW or chassis rails of the electric vehicle. The Al casting includes a bottom wall, a side wall with a pair of rails that are securely attached to the BIW or chassis rails of the vehicle, and a plurality of cross members. The bottom wall, the side wall, and the plurality of cross members define a structural enclosure with a plurality of battery compartments and at least one crush zone, and the structural enclosure is load bearing member of the electric vehicle.

Abstract: A part includes a sheet metal component having a predefined shape and at least one additively manufactured reinforcement deposited on, metallurgically bonded to, and extending along a surface of the sheet metal component. The at least one additively manufactured reinforcement can be a directed energy deposition (DED) reinforcement rib. Also, the at least one additively manufactured reinforcement can be deposited on the piece of sheet metal before the piece of sheet metal is formed into the predefined shape, or in the alternative, the at least one additively manufactured reinforcement can be deposited on the piece of sheet metal after the piece of sheet metal is formed into the predefined shape.

Abstract: This disclosure details multi-purpose brackets for mounting accessory devices within vehicle cargo spaces. Exemplary multi-purpose brackets include a doubling flange, a first opening formed through the doubling flange, and a second opening formed through another location of the bracket. A first accessory device may be mounted within the first opening, and a second accessory device may be mounted within the second opening. The multi-purpose bracket may be formed in a stamping process that involves folding and clinching the doubling flange to a platform of the bracket.

Abstract: This disclosure details multi-purpose brackets for mounting accessory devices within vehicle cargo spaces. Exemplary multi-purpose brackets include a doubling flange, a first opening formed through the doubling flange, and a second opening formed through another location of the bracket. A first accessory device may be mounted within the first opening, and a second accessory device may be mounted within the second opening. The multi-purpose bracket may be formed in a stamping process that involves folding and clinching the doubling flange to a platform of the bracket.