Abstract: A method includes extruding an elongate member that has a longitudinally extending cross section, bending the elongate member about a first axis and subsequently about a second axis, non-parallel to the first axis, to form a vehicle body component.

Abstract: A hydroform tube includes a first end and a second end. The hydroform tube includes a plurality of sides including a first side and a second side, and a fillet extending from the first side to the second side. The first side, the second side, and the fillet extend from the first end to the second end. The plurality of sides form different shapes at two cross-sections between the first end and the second end. The tube has substantially the same perimeter P at all cross-sections from the first end to the second end. The fillet has a radius R. The radius R is defined by a same formula at all cross-sections from the first end to the second end.

Abstract: A vehicle body component is provided. The vehicle body component includes an extruded elongate member that has a longitudinally extending cross section. The elongate member includes a first section that extends along a first axis, a second section that extends from the first section along a second axis, and a third section that extends from the second section along a third axis, wherein the first axis and the third axis are non-coplanar with respect to each other.

Abstract: A vehicle body component is provided. The vehicle body component includes an extruded elongate member that has a longitudinally extending cross section. The elongate member includes a first section that extends along a first axis, a second section that extends from the first section along a second axis, and a third section that extends from the second section along a third axis, wherein the first axis and the third axis are non-coplanar with respect to each other.

Abstract: A shock tower assembly includes a cast shock tower body composed of magnesium or magnesium alloy and at least one steel bridging bracket. An insulating adhesive layer is formed between the tower body and the bracket. A mechanical fastener is used for fastening the tower body to the bracket. One or more structural ribbings are formed on the tower body. The mechanical fastener may be selected from any of several mechanical fasteners, including self-piercing rivets. Alternatively, a screw boss may be formed for receiving a screw. The rivet may be inserted from the bracket into the shock tower body or from the shock tower body into the bracket in which case an insulating layer is positioned between the head of the self-piercing rivet and the cast shock tower body. A sealant is preferably formed along the intersection of the cast shock tower body and the steel bridging bracket.

Abstract: A method of varying vehicle width on a single platform includes providing a plurality of vehicles, where each vehicle includes a side sill extending longitudinally along a lower portion of a vehicle body. The side sill defines a door opening interface on each opposing side of the vehicle body. Each of the plurality of vehicles also includes a floor panel extending laterally across a width of each vehicle. The floor panel is joined at a lateral edge to the side sill. The method also includes maintaining a common lateral position of the joint between the floor panel and the side sill across each of the plurality of vehicles. The method further includes positioning the door opening interface at first lateral position corresponding to a first one of the plurality of vehicles and at a second lateral position corresponding to a second one of the plurality of vehicles.

Abstract: A method of varying vehicle width on a single platform includes providing a plurality of vehicles, where each vehicle includes a side sill extending longitudinally along a lower portion of a vehicle body. The side sill defines a door opening interface on each opposing side of the vehicle body. Each of the plurality of vehicles also includes a floor panel extending laterally across a width of each vehicle. The floor panel is joined at a lateral edge to the side sill. The method also includes maintaining a common lateral position of the joint between the floor panel and the side sill across each of the plurality of vehicles. The method further includes positioning the door opening interface at first lateral position corresponding to a first one of the plurality of vehicles and at a second lateral position corresponding to a second one of the plurality of vehicles.

Abstract: A shock tower assembly includes a cast shock tower body composed of magnesium or magnesium alloy and at least one steel bridging bracket. An insulating adhesive layer is formed between the tower body and the bracket. A mechanical fastener is used for fastening the tower body to the bracket. One or more structural ribbing are formed on the tower body. The mechanical fastener may be selected from any of several mechanical fasteners, including self-piercing rivets. Alternatively, a screw boss may be formed for receiving a screw. The rivet may be inserted from the bracket into the shock tower body or from the shock tower body into the bracket in which case an insulating layer is positioned between the head of the self-piercing rivet and the cast shock tower body. A sealant is preferably formed along the intersection of the cast shock tower body and the steel bridging bracket.

Abstract: A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Abstract: Various approaches for forming holes onto a sheet-metal assembly are described. In one implementation, a sheet-metal assembly is received through a conveyor system within a manufacturing cell. Once received, the type of sheet-metal assembly is identified based on associated information. Corresponding to the identified sheet-metal assembly, a set of position coordinates corresponding to one or more points on the sheet-metal assembly are obtained. Subsequently, a work-performing apparatus may be used for forming holes onto the sheet-metal assembly, at one or more points on the sheet-metal assembly.