NEWS RELEASE

MAGNA DEMONSTRATES LIGHTWEIGHTING EXPERTISE WITH

ULTRALIGHT DOOR MODULE
Team reimagined a door architecture from scratch
Ultralight design achieves 42.5-percent mass savings
Applies to 70 percent of the light vehicle market
HIGHLIGHT
DETROIT, Mich., January 9, 2017 Magna International Inc., in cooperation with the U.S.
Department of Energy (DOE) and partners FCA US and Grupo Antolin, announced it has
developed a new, ultralight door architecture that achieves the project objective of 42.5 percent
mass savings compared to an average current production door. Making the announcement at
the 2017 North American International Auto Show, Magna and its project partners presented a
solution to further help global automakers meet emissions standards and reduce fuel
consumption through lightweighting.

Magnas advanced engineering team a collaborative

effort between the companys corporate R&D and various
product groups combined its unique, full-vehicle
perspective on the design of a drivers-side door with an
inventive mix of materials and technology to tackle the
challenge of significant weight reduction. This was
developed in less than 10 months while keeping the cost
within accepted industry parameters and providing a solution
that applies to approximately 70 percent of the light vehicle

Ultralight door module achieves

42.5% mass savings

market.

The team started from scratch and reimagined the way we think about the design, development
and material-use of a door architecture, said Swamy Kotagiri, Chief Technology Officer, Magna
International. Building on our significant expertise in lightweighting from previous DOE projects,
the team leveraged our broad product-development expertise and tackled this challenge in a
cost-effective manner while meeting safety, durability and functionality requirements.
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Magna built on its know-how from the development of the Multi-Material Lightweight Vehicle
(MMLV) with the DOE and Ford in 2014, and took it a step further in creating a solution for this
advanced ultralight door project.

A key innovation associated with the development of the ultralight door includes integration of
Magnas SmartLatch electronic latch system. This eliminated the need for mechanical
hardware and enabled the development of a unique carrier module with integrated glass guides
and lift capability of a lightweight hybrid glass laminate, an industry first.

The door-in-white assembly makes extensive use of aluminum, which achieves approximately
half of the total mass reduction of the door assembly. Overall, the project makes use of
materials readily available today that can easily be made using existing manufacturing
processes, without a significant increase in production costs or changes in body-shop
infrastructure.

Grupo Antolin contributed its know-how in the design and manufacture of interior trim
components to contribute to the significant mass reduction. The application of advanced
molding technologies and polymers contributed approximately 7 percent to the total mass
reduction.

The ultralight door development included intensive simulation efforts, passing all safety and
durability testing in the process. The next steps include manufacturing full-scale prototype door
assemblies, performance tests and safety tests to validate the design, with the goal of being
available for use in production vehicles by the fall of 2020.

The FCA US engineering team has been an integral part of the design and development of the
ultralight door, providing engineering collaboration to confirm compatibility with existing
assembly operations as well as CAE durability, fatigue and safety analysis. FCA US plans to
conduct testing of prototype door assemblies and full vehicles to validate the results of the
predictive simulation.

This material is based upon work supported by the Department of Energy, Office of Energy
Efficiency and Renewable Energy (EERE), under award number DE-0007306.
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TAGS
Automotive innovation, public-private partnership, automotive lightweighting, lightweight door
INVESTOR CONTACT
Louis Tonelli, Vice-President, Investor Relations
louis.tonelli@magna.com, 905.726.7035
MEDIA CONTACT
Tracy Fuerst, Global Director of Corporate Communications & PR
tracy.fuerst@magna.com, 248.631.5396

ABOUT MAGNA INTERNATIONAL

We are a leading global automotive supplier with 312 manufacturing operations and 98 product
development, engineering and sales centres in 29 countries. We have over 155,000 employees
focused on delivering superior value to our customers through innovative products and
processes, and World Class Manufacturing. We have complete vehicle engineering and
contract manufacturing expertise, as well as product capabilities which include body, chassis,
exterior, seating, powertrain, electronic, active driver assistance, vision, closure and roof
systems. Our common shares trade on the Toronto Stock Exchange (MG) and the New York
Stock Exchange (MGA). For further information about Magna, visit our website at
www.magna.com.
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