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| Using technology proven in the aerospace and motorsport industries, we introduced a bonded, anodised aluminium body structure – a first for the commercial vehicle sector. This design helps unlock a new level of operator benefits in terms of durability, weight, lifespan and total cost of ownership. |
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| THE FUNDAMENTALS |
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| VN5 is built on an aluminium monocoque construction, which integrates the frame into the body structure, creating a unitised body (unlike body-on-frame construction, which entails mounting the body of the vehicle on a chassis). This cuts significant weight out of the vehicle, helping improve fuel economy. |
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| The aluminium components are glued together using an incredibly strong hot cure adhesive. The glue remains dormant until the entire structure is baked in an oven at 180°C for 20 minutes. Once cured, the adhesive becomes rock solid, turning the frame into a single, remarkably rigid structure. |
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| STRONGER, LIGHTER & LASTS LONGER |
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| The resulting bonds are more than twice as strong as traditional welding. This was tested on a 100mm aluminium strip, with the arrow representing the direction of the force applied. The upper welded joint failed at a load of 16kN. The bonded joint remains strong until around 34kN (3.4 tons) – under this force, the aluminium surface itself gives way. |
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| VN5’s monocoque structure also gives the van immense strength and impact resistance, as aluminium can absorb twice as much energy as mild steel, pound for pound. |
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| Weighing just 370kg, the body structure effectively combines high torsional rigidity with lightweight construction. It is around 30% lighter than the equivalent steel structure – a crucial saving, especially in an electric vehicle, where most of the weight comes from the batteries. A conventional steel body and frame would add significantly more weight, decreasing performance and range. |
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| Unlike steel, aluminium does not rust, and all 400+ aluminium components are anodised to further increase corrosion resistance. |
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| The result is a van that stays productive for longer. In fact, VN5 can last twice as long as a conventional van – and its long life expectation will lead to excellent residual values. |
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| ENVIRONMENTAL BENEFITS |
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| The aluminium used in the body structure is made from recycled material, and is 100% recyclable so the end of the vehicle’s life is greener too. The Department of Energy found that an aluminium vehicle can achieve a 20% reduction in total lifecycle energy consumption and a 17% reduction in CO2emissions. |
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