For Release: Wednesday, June 17, 2015, 8 a.m. EDT
5 Ways Chevrolet Made 2016 Malibu Segment’s Lightest
Approximately 136 kg weight reduction enhances efficiency, driving
dynamics
Oshawa, Ontario (Wednesday, June 17, 2015) – Engineers developing the
2016 Chevrolet Malibu put the new midsize sedan on a strength-training program,
making it sweat out a pound here and a gram there, in a quest to make it more fuel
efficient, stronger and safer.
The result is an all-new Malibu that is nearly 136 kilograms (300 lbs.) lighter than
the current model – an achievement that not only gives it the segment’s lightest
base curb weight, but also contributes to a GM estimated city fuel consumption of
4.9 L/100km for the hybrid model and 6.4 L/100km highway for the 1.5L turbo
base engine. A lighter curb weight will also improve ride and handling.
“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 Jesse Ortega, chief engineer. “That’s what we’ve done with the 2016 Malibu,
with the mass savings spread throughout the vehicle, providing greater overall
balance, a more responsive and agile driving experience and lower fuel
consumption.
“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,” said Ortega. “The aim
was to make Malibu the most mass-efficient car in its class.”
Here are five of the most noteworthy mass-saving achievements:
1. Leaner, stronger body structure
More than a third of the 2016 Malibu’s mass savings – approximately 54 kilograms
(120 lbs.) – comes from its all-new body structure, which features greater use of
high-strength steels, enabling the use of thinner components in some areas, while
delivering comparable or better crash performance.
The stronger-yet-lighter structure is also stiffer than the current model, which
allowed suspension components to be tuned more precisely. Engineers had less
body flex to account for, body flex, which contributes to the new Malibu’s sharper
ride-and-handling reflexes.
Development of the Malibu’s structure is the result of extensive computational
analysis, which employed sophisticated modeling programs to simulate dozens of
design iterations that indicated the most strategic placement for high-strength steel
elements such as the pillars and rockers – all while maintaining higher targets for
strength, stiffness and crashworthiness.
“The analysis took the guesswork out of the Malibu’s development, allowing the
chassis to be developed with the just-right level of structural components,” said
Amir Sewani, structural engineer. “After the structure was determined, we started
looking at all the components that are attached to it, evaluating where they could
be optimized for lower weight.”
2. Greater use of aluminum
Light and strong, the incorporation of more aluminum in the 2016 Malibu
contributes significantly to its lower weight. Examples include an aluminum hood
that is 3 kilograms (6.6 lbs.) lighter than current model’s steel hood, and aluminum
suspension knuckles and chassis components, as well as lighter mounts.
An additional benefit of the aluminum suspension components is reduced un-sprung
mass, which contributes to the Malibu’s responsiveness.
3. Streamlined instrument panel assembly and lighter power accessories
New power window regulators collectively save 1.9 kilograms (4.2 lbs.) – a 34percent reduction over the current model, while another 1 kilogram (2.2 lbs.) was
saved by reducing the complexity of components within the instrument panel. That
included simplified construction with more integrated parts – and fewer components
in the assembly.
Even the centre console has a streamlined, one-piece structural shell that is 0.8
kilograms (1.75 lbs.) lighter than the current model.
4. Lighter leather seats and other soft materials
The Malibu’s available leather seats are collectively 18.4 kilograms (40.6 lbs.)
lighter than the current model. Additionally, about 0.7 kilograms (1.5 lbs.) was
saved with new trunk liner material and another 0.5 kilograms (1.1 lbs.) was
shaved with new, proprietary interior carpet material that also is more durable than
the current model.
5. A lighter engine
The 2016 Malibu’s all-new, standard 1.5L turbo engine is 39 kilograms (86 lbs.)
lighter than the current model’s standard 2.5L engine, while delivering comparable
performance. Its lighter weight also enhances the Malibu’s front-to-rear weight
balance – another contributor of the car’s more responsive driving experience.
The 2016 Malibu goes on sale in the fourth quarter of 2015. It will be offered in L,
LS, LT and Premier trims, as well as a Hybrid model.
Curb Weights Compared
CURB WEIGHT
2016 Chevrolet Malibu 1LT (1.5L
Turbo)
2015 Ford Fusion SE (2.5L)
2015 Toyota Camry LE (2.5L)
2015 Hyundai Sonata SE (2.4L)
2015 Honda Accord LX (2.4L)
2015 Nissan Altima SV (2.5L)
2015 Kia Optima EX (2.4L)
3,100 lbs (est.)
HIGHWAY FUEL
CONSUMPTION (L/100KM)
6.4 (GM est.)
3,461 lbs
3,240 lbs
3,252 lbs
3,192 lbs (man. trans.)
3,206 lbs
3,272 lbs
7.0
6.9
6.7
6.9 (man. trans.)
6.2
6.9
FAST FACT: High-strength steel alloys typically contain magnesium to
enhance strength.
About Chevrolet in Canada
Founded in 1911 in Detroit, Chevrolet is now one of the world's largest car brands, doing
business in more than 115 countries and selling more than 4.8 million cars and trucks a
year. Chevrolet provides customers with fuel-efficient vehicles that feature engaging
performance, design that makes the heart beat, passive and active safety features and
easy-to-use technology, all at a value. More information on Chevrolet models can be found
at www.chevrolet.ca, on Facebook at http://www.facebook.com/chevroletcanada or by
following @ChevroletCanada on Twitter.
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