I am thinking of a vehicle made with multi-material 3D printer. The complicated curved fuselage cage meeting nowadays safety standards/ including seats for passangers will be made one piece 3D print, of a composite material, such as ABS plastic compound LNP polymeres /combination of about 80 percent ABS plastic and 20 percent carbon fiber reinforcement is tough as metal. It may look like too lightweight, but the carbon-reinforced ABS plastic is stronger and denser than it appears as they say in LM/ They are planning to manufacture an airbus with 3Dprint where the complicated curved fuselage will be done this way and first of all it should be 65% lighter than with traditional manufacturing methods /ref: http://www.forbes.com/sites/parmyolson/2012/07/11/airbus-explores-a-future-where-planes-are-built-with-giant-3d-printers/
Sure there are many more forwardlooking options of HIGH-TECH MATERIALS used to be 3Dprinted like: nanotechnology and nanomaterials, graphene /200 times stronger than steel, but as thin as an atom/, aerogel /lightest materials/ or smarthphone glass /half the weight of conventional laminated glass/ where we can move over to get the most of LEIGHTWEIGHTING /ref: http://www.autoalliance.org/auto-innovation/high-tech-materials/
According to stricter regulations new level of innovation must be applied in all parts of vehicle. We must get weight / cost and performance BALLANCED.
After we change the powertrain to electric / hybrid and by lightweigting programme we can get into vehicle more batteries, change the capacicty of fuel tank, we use a small combustion engine /let's assume we run out of petrol in a desert than this engine charges the batteries again on./ As they did by example with Range Rover Sport /SVT/ /ref: http://www.netcarshow.com/land_rover/2014-range_rover_sport/ or Ford F-150 Raptor only by using its all-aluminium monocoque Lightweight technologies cut weight by up to 420kg. Althoug there has not to be used an combustion engine in concept becouse of all his comlicated components. It's all alluminium III body could stay optional. I'd use in-wheel Protean Electric motors. And the newest carbon batteries. Their amount is depending on single charge range we are planning the concept to be eligible to achieve. More than 300 miles as we are looking 10 yeras forward. /ref: http://www.teslamotors.com/models, http://www.lightningcarcompany.co.uk/Lightning/home.html
As we reduse the mass of the whole body, still there must be aerodynamic rules taken into consideration while fewer power /less weight in powertrain/ is needed. Not forgetting about rolling resistance and the aerodynamics /plus active aero./ of a teardrop capsule body design of this concept should be running under /Cd=0.20/ . /ref: http://motorburn.com/2014/01/12-of-the-most-aerodynamic-cars-in-production-right-now/
I am thinking of inovative wheels too. They shold be large diameter and made of three thin rings with narrov tread with cornering function motorcycle way--leaning into bends like on motorbikes. So the grip stays huge enough but rolling resistance drops radically. /ref: https://www.youtube.com/watch?v=J5zG6DPMmTU/
At the end specialized engineering software + process changes will make the fabrication first of all diferent and also completly unrelayed on experiences on steel welded structures. Here we'll get a complete innovative new product RENOVATO.
see online: https://launchforth.io/romanbasti/renovato/overview/