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Audi’s could be made much lighter if the tech was more affordable.

Audi’s could be made much lighter if the tech was more affordable, they admit they have the technology to make lighter cars, but current prices for the latest materials dictate that it is not cost effective at present.

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The next generation of lightweight materials is still too expensive to make them viable for mass production, a senior engineering source at Audi has revealed.

The German manufacturer’s research has suggested that its customers want at least 300 miles of range per charge in any electric Audi. But the firm faces a battle to introduce the weight savings and battery technology that can deliver that sort of range for a cost customers are willing to pay.

A senior insider in Audi’s engineering division said: “Batteries are heavy so it makes sense to reduce the weight of the car. But as with all weight-reduction materials you have to look at the costs and how you bring the materials together in the factory.

“For example, if you have multi-material bodywork -if you have steel, for example, in combination with aluminum and carbonfibre – you can glue it, rivet it or you can weld it. After that, for example, there’s the painting process and anti-corrosion process – all done at quite high temperatures, prompting the materials to work against themselves. We need a lot of know-how of how to do that, and it’s expensive, too.”

The German manufacturer has learnt from research that many of its customers want at least 300 miles of range per charge in an electric Audi. However, although the weight saving technology to achieve this goal is available, it is still too expensive for application over a larger number of cars.

A senior insider for Audi told Autocar: “Batteries are heavy so it makes sense to reduce the weight of the car. But as with all weight-reduction materials you have to look at the costs and how you bring the materials together in the factory.

“For example, if you have multi-material bodywork – if you have steel, for example, in combination with aluminium an carbon-fibre – you can glue it, rivet it or you can weld it. After that, for example, there’s the painting process and anti-corrosion process – all done at quite high temperatures, prompting the materials to work against themselves. We need a lot of know-how of how to do that, and if it’s expensive, too.”

Audi is due to launch an all-electric SUV first because it is easier to have space for a larger amount of batteries in a bigger car. The source added: “You need a big car for the space of the batteries to realise 300 miles.

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