The Hypercar company and the Hypercar program are used as an example of how systems integration can be a focus and key enabler in challenging product development efforts

1. Systems Focused Product Development of the Hypercar April 29, 2002

2. Hypercar, Inc.

5. creating the team

9. creating the revolution

11. the Revolution…

12. vehicle attributes Comfortably seats five 95% adults Can ascend a 44% grade with 1/2-ton payload 13.0 seconds 8.3 seconds A B 18 miles = 1 Gallon A B 99 miles = 1 Gallon 99 20 18 56 8.3 9.0 8.4 13 330 320 340 NA SULEV NA NA ULEV 1.96 2.1 2.3 NA 857 1832 1873 1330 460 466 408 NA 4564 4580 4843 4217 1830 1815 1783 1746 1548 1548 1719 1589 = 1873 kg lotta mass lotta mass lotta mass lotta mass = 857 kg noso much mass noso much mass 44 NA NA NA .26 .36 .43 .27 Ford Explorer Revolution Ford Escape Revolution Emits only hot water vapor H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2 H 2

13. package/configuration 35 kw Fuel Cell 5 ksi Hydrogen tanks 35 kw Load leveling NmH batteries Motors for each wheel 25kw fronts 10kw rears Power converter Adaptive suspension HVAC Composite suspension Thermal Management

16. occupant environment

17. weight assessment Hypercar, Inc. Confidential and Proprietary Information

18. design team in action

19. the advanced composite solution

20. advanced composites SOTA Need is for stiffness and stability, energy management and load paths, NOT necessarily strength Stiffness (lbs/in 2 x 10 6 ) Density (lbs/in 3 x 10 - 2 ) Raw Matl . Cost ($/lb) Stiffness (lbs/in 2 x 10 6 ) Density (lbs/in 3 x 10 - 2 ) Raw Matl . Cost ($/lb) 0 100 200 300 400 500 600 700 800 900 Dry Tow RTD Rod RTD Uni 220F Dry Uni RT Wet Uni 220F Wet Uni RTD Quasi 220F Wet Quasi RTD OHT 220F Wet OHT 200 F 7075 Sheet Strength (ksi)

21. by design Built in reverse order to conventional vehicle Integrated side intrusion beam and hardware cassette incorporating hinges, latches, and window mechanisms Door inner panel doubles as interior trim surface with add on FMVSS padding where required Exterior skin is self-colored, easily removable, damage tolerant, and swaged for stability Door inner incorporates arm rests for controls Door pocket is formed by applying a front piece to the door inner Energy absorbing foam inserts S1 S2 S3 S4 B1 B2 B3 B4 B5 C3 C2 C1 S5 B6 B1 B2 B3 B4 B5 B6

22. structural analysis Crash Energy Management and Repairability Speed: 6 Mph 15 Mph 35 Mph > 35 Mph Damage: Deformation of bumper Bumper and beam destroyed Subframe destroyed Safety cell damage occurs Repair: Self repairing, no damage Replace bumper system and heat exchangers Replace complete subframe Impractical per convention

23. Thank you!