The platform shaping the future
The claim for the PPE41
A new generation of vehicles presents developers with several challenges. Increasing demands for range and charging speed, coupled with shorter development cycles and the need for cost optimization, make this an especially difficult time for developers. The PPE41 is designed to address these challenges precisely.
While earlier platforms for internal combustion engines offered modular solutions, integrating them into battery electric vehicles (BEVs) requires significantly more flexibility. Traditional architectures strictly defined the engine compartment and powertrain, but electric powertrains open up new degrees of freedom that the PPE41 leverages.
Scalability as the key
The PPE41 is designed for different wheelbases, whether it’s a hatchback or an SUV. Its variable wheelbase and flexible overhangs enable the production of numerous models based on a single platform.
This scalability reduces development time and production costs because large parts of the electric vehicle architecture remain identical.
Technical Highlights of the PPE41
The body architecture of the PPE41 is designed for maximum efficiency.
- Drivetrain options: Rear-wheel and all-wheel drive options are available.
- Battery technology: High-voltage batteries with varying capacities are integrated depending on range and performance requirements.
- 800-volt technology: This technology enables particularly fast charging and minimizes downtime.
The engineering capabilities of the csi Group
Implementing a platform like the PPE41 is a complex engineering project. ALU-CAR’s experts drove forward collaborative development with AUDI AG and carried out the technical design work.
Achieving a balance between design freedom, technical feasibility, and production optimization is particularly challenging. Scalability only works if every dimension, interface, and assembly position is thoroughly thought through in advance.
Involving ALU-CAR from the initial concept to series production was a decisive advantage, especially regarding the parametric-associative CAD system, which is most effective when all phases are processed end-to-end.
Thanks to close collaboration within the csi Group, particularly regarding experience in developing complex body structures, a platform has emerged that forms the basis for several new model series today.
Practical implementation of the platform architecture
The development of the PPE41 platform was characterized by high technical precision and efficiency standards. Early on, ALU-CAR, under the direction of AUDI AG, conducted preliminary studies on the body-in-white architecture and battery housing, focusing specifically on lightweight steel hybrid construction. The extensive use of hot-formed parts and the integration of Tailored Rolled Blanks (TRBs) significantly contribute to weight optimization and improved crash performance.
To ensure the smooth, parallel development of high- and low-floor variants, the project was divided into four areas in the second phase: front end, center floor, rear end, and project management and organization (PMO). This structure enabled efficient coordination between the participating teams and the targeted implementation of the platform requirements.
The csi Group played an active role in the design process, working closely with the engineering, tooling, and manufacturability assessment teams. This involvement was made possible through the lightweight construction specialists at ALU-CAR. Detailed alternative concepts and analyses were made available in a very short time. The group's extensive experience in developing complex body structures, particularly in the areas of multi-material mixes, assembly sequences, and associated joining technologies, and its strong reputation in body-in-white development, were crucial to successfully realizing the PPE41 as a forward-looking platform.
