General Motors has highlighted the weight-saving features in the 2016 Chevrolet Malibu, which is 300 pounds lighter than its predecessor.
More than a third of the overall savings comes from the redesigned body structure, which utilizes thinner high-strength-steel components in some areas. The structure is lighter yet stronger and stiffer, improving suspension tuning and meeting or exceeding crash-test performance compared to the previous generation.
Engineers also opted for aluminum when designing the hood, suspension knuckles and other chassis components. Switching to aluminum suspension components brings the added benefit of lower un-sprung mass, further refining the Malibu’s handling.
The interior was also crafted with weight in mind, dropping more than four pounds just by switching to lightweight power-window regulators. Additional savings comes from a simplified instrument panel, and a one-piece center console. Available leather seats are said to be collectively 40 pounds lighter than the outgoing components.
“Imagine you’ve got a 300-pound lineman riding on the roof of your car and he decides to jump off – you’re going to notice a change in performance immediately,” said chief engineer Jesse Ortega. “The Malibu team was challenged to look for weight savings in every area of the vehicle, no matter how small, because every gram adds up.”
The weight savings contributes to an increase in fuel efficiency, bringing the base model’s highway rating up to 37 mpg. The hybrid variant, meanwhile, fetches up to 48 mpg in the city.
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