Objective: Redesign of the Zap Alias to improve manufacturability, improve occupant and component packaging and improve aesthetics.
Strategy: Our process began by conducting studies of the current packaging. Changes were made to the overall height and width of the vehicle to ensure passengers could fit comfortably and batteries could be packaged correctly. Modifications were made to ensure that the doors could open properly and the windows could roll down. Updates were also made to the front end for function and style and to ensure the vehicle could pass federal regulations.
Results: Redesign of complete body was achieved in rapid time and a production plan developed using advanced composites and manufacturing techniques. The Alias was recently voted the most stylish vehicle in the Automotive X-Prize.