Concept: Lotus Hot Wheels

Group Lotus plc has teamed up with Hot Wheels®, the famous global die-cast brand, to design, develop and produce a Lotus Hot Wheels® Concept vehicle. This 1:5 scale model was on display to the world at the annual SEMA Show at the Las Vegas Convention Centre between 29th October and 2nd November 2007, and a 1:64 scale version of the design will become part of the Hot Wheels® product range in spring 2008.

To celebrate its 40th anniversary next year, Hot Wheels® approached Lotus and other world leaders in he automotive industry with the challenge for each company to produce a vehicle that embodies its own engineering philosophy and brand. The result from Lotus is a stunning open-top two seat sports car concept. Russell Carr, Head of Lotus Design said; "This was a dream job for the design team because, for many of us, when we were children, it was Hot Wheels® that first ignited our passion for cars and design.

Lotus Design's international reputation for designing visually dynamic and exhilarating sports cars perfectly fitted the brief for this programme and we relished the opportunity to design a concept that was free from the typical technical and legal constraints of a full size car. In addition the design offered unique challenges because it has to work as a toy and we therefore had to remember how specific views, features and tactile qualities of toy cars fascinated us as children. I am very proud of the final design by Steven Crijns that succeeds in being both instantly recognisable as a Lotus and a Hot Wheels® Car. Steven Crijns, Design Manager at Lotus Design and creator of this concept design explained; "Hot Wheels® cars are barely 75mm long, so specific attention went to create a bold shape that would work well at this scale. Another challenge was to create an exciting design that would work well as a toy. The car needed to be recognisable as a Lotus without having to turn it over to look at the badge underneath, so I took elements from the Lotus Elise and Lotus Exige such as the headlight design, the Lotus 'mouth', the pronounced wheel arches and trademark bonnet graphics. I was keen for the design to express the Lotus philosophy of performance through lightweight: the shrink wrapped body is kept to an absolute minimum to save weight. The dynamic voluptuous curves make the car look agile and fun to drive. Bold aerodynamic aids are incorporated to achieve exceptional Lotus handling. The top exit radiator at the front, a distinctive Lotus design feature, the rear diffuser and a large rear wing all provide down-force helping the vehicle stick to the road. In addition, large side air intakes and an open rear end aid engine breathing. Inside the car, the exposed centre spine is part of the structure and incorporates the switches and gear linkage and supports the rear wing."

Mike Kimberley, Chief Executive Officer of Group Lotus Plc said "We are delighted to have worked with Hot Wheels®, who share our passion and enthusiasm for all things automotive. Lotus Design has a global reputation and is responsible for the design of all Lotus cars, including Lotus Europa, Exige and iconic Elise and many designs for our engineering clients globally. The same design team who created this stunning concept is also designing our new range of cars, the first of which, codenamed Project Eagle, will go into production at the end of next year."

The New Lotus Eco Elise

The Lotus Eco Elise project promotes a different perspective on "green", one which does not revolve solely around tailpipe CO2. This holistic approach is in keeping with the progressive Lotus culture, driving Lotus to become the world's green automotive consultancy.

Sustainable materials, hemp, eco wool and sisal have been developed for body panels and trim and, combined with hi-tech water based paint solutions, showcase new affordable green technologies. The green credentials of the technology on show in the Lotus Eco Elise have been analysed throughout the lifecycle of the car.

A green gear change display has been integrated into the dashboard to promote greener driving as well as a weight reduction programme, illustrating the holistic approach taken. The energy expended to manufacture the car has been evaluated, working to the 3R's - Reduce, Re-use and Recycle.

Mike Kimberley, CEO of Group Lotus plc commented "This Eco Elise is a great example of the advanced and affordable green technologies Lotus is developing. We are at the cutting edge of environmental technology and are determined to push forward with our green agenda. The Lotus brand values of lightweight, fuel efficient, and high performance are more relevant today than they ever have been. We are keen to ensure that Lotus as a company and its products offer an ethical, green option that appeals to our customers".

The project focuses on developments in:

• Sustainable materials
• Cleaner manufacturing processes
• Renewable energy generation
• Reducing carbon miles
• Efficient driving techniques
• Weight reduction

The renewable materials have been incorporated into the project, with hemp, eco wool and sisal providing natural, biodegradable engineering materials. Cleaner manufacturing processes have been sought, utilising the latest water based paint technology. Using this paint system saves energy and reduces emissions of solvents from the paint shop. Solar panels have been set into the hemp hard top to help power the electrical systems and give a means of renewable energy generation.

With the use of locally farmed hemp, the carbon miles to produce the Lotus Eco Elise are reduced, in keeping with the holistic approach to this vehicle. The Lotus Eco Elise puts an emphasis on efficient driving techniques by using an "economy" gear change display to improve fuel efficiency and promote greener driving. The car has undergone a weight reduction programme to add a little extra lightness, assisting in more economical, greener driving.

Sustainable materials

Sustainable hemp technical fabrics have been used as the primary constituent in the high quality "A" class composite body panels and spoiler. The renewable hemp has exceptional material properties that make for a very strong fibre. Historically hemp has been used in the manufacture of rope, illustrating the great strength of the material.

The hemp fibres have also been used in the manufacture of the lightweight Lotus designed seats. An additional benefit of using hemp is that it is a natural resource that requires relatively low energy to manufacture and absorbs CO2 whilst growing as a plant through natural photosynthesis. This hemp material is used with a polyester resin to form a hybrid composite, however it is hoped that a fully recyclable composite resin will be viable in the short-term future.

The Lotus Eco Elise seats are upholstered in a durable yet, biodegradable woollen fabric that has been given the EU Flower certificate to exemplify its environmental credentials. This new material is ethically produced and does not use any dyes or harmful processing. In fact the colour is created from the selection of sheep breeds used to produce the wool for the yarn, which increases the natural feel of the wool and reduces the processing of the cloth.

Sisal is a renewable crop that, like hemp, is used for its strong material properties. Sisal has been used for the carpets in the Lotus Eco Elise, as it is a tough, abrasion resistant material. The use of these materials illustrates the capability at Lotus of utilising new, advanced materials and the flexibility of the manufacturing facilities.

Cleaner manufacturing processes

Whilst improving the green credentials of the Lotus production facilities, the Lotus Paint Facility, in partnership with Du Pont has developed a totally water-based paint system. This paint solution includes primer, colour coat and lacquer, and it is the first time that it has been possible to hand spray a water based "A" class production paint finish.

In using this progressive water based technology, Lotus is able to achieve impressive savings in energy consumption due to the low cure temperature this paint requires. An additional benefit of this paint system is the reduction in emissions of solvents, all of which contribute to substantial cost savings for Lotus. This is a result of the unique collaboration with Du Pont in pushing forward low-volume paint spraying technology. This technology is anticipated to be available in production cars in the near future.

Renewable energy generation

The hemp hard top on the Lotus Eco Elise has two flexible solar panels neatly embedded in the roof, contributing power to the electrical systems and saving energy that would be drained from the engine.

The solar panels have been integrated into the hard top to illustrate the feasibility of applying this technology. This application shows the installation of solar panels into a composite "A" class panel with a double curvature. Using this technology on a greater number of panels would make it possible to provide more power, especially on a larger vehicle.

Reduction in carbon miles

The hemp fibres have been farmed in East Anglia, thus reducing the carbon miles incurred in the production of this Elise. Lotus Manufacturing has component manufacturing facilities and a paint facility at its headquarters in Hethel, Norfolk, with another manufacturing site a short distance away in Norwich. The company operates a carefully managed logistics system operating between sites to improve efficiency, reduce costs and carbon miles. This is a Kanban driven barcode system that has been adopted by key suppliers. The process also uses packaging that is recycled many times over to eliminate waste.

Efficient driving techniques

Lotus cars have red shift lights to help drivers extract the maximum performance from the engine. However for the Lotus Eco Elise, Lotus designed software has been developed to assist drivers in maximising the fuel efficiency of the engine. A green gear shift display has been integrated into the instrument panel to ensure that gears are changed at the optimum point to reduce emissions and save fuel.

Weight reduction

"Performance through light weight" is so synonymous with Lotus. The reduction in mass improves the handling and braking performance and also reduces the effort required to accelerate the car. The weight reduction philosophy has even extended to the audio system with an exceptionally lightweight stereo and speaker system from Alpine saving 1.5 kg (3.3 lbs). The system uses MP3/ iPod technology in a sleek modern design.

The Lotus Eco Elise uses special lightweight wheels that reduce the unsprung mass and contribute a weight saving of approximately 15.8 kg (34.8 lbs) over the already super light Elise wheels. The weight saving programme for the Lotus Eco Elise has resulted in a total saving of around 32 kg (70.5 lbs) over the feather light Elise S, which reduces the fuel required to drive the car.