Hypercar, Inc. is a private company focused on advanced technology development for energy-efficient automotive design, leveraging aerospace and motorsport expertise. Their innovative vehicle design promises high performance with zero emissions and significant fuel efficiency, targeting a mainstream crossover market. The document details the company's unique approaches to product development and composite materials aimed at optimizing vehicle performance and manufacturing processes.

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

2. Hypercar, Inc.

3. what is Hypercar, Inc. Private advanced technology development company focusing on “uncompromised” energy efficiency in automotive design Design, engineering, and technology development and validation for OEMs and Tier I and II suppliers Core competencies: Skunk Works based, production oriented whole system product development Advanced composite structure design and production solutions Vehicle level digital integration and energy management Products: IP development, validation, and transfer Applications engineering services: includes programs to develop, validate, produce and license whole vehicle and system-level production innovations Collaborative whole-vehicle and system level production opportunities via JV’s or strategic partnerships Team: committed, experienced, high-performance individuals Skunk Works ® development process merged with best practice of automotive, aerospace, and motorsport experience

4. system efficiency and technology Reduce platform loads: Mass/inertia Thermal loads Aerodynamic drag Rolling resistance Power transmission efficiency New applications of technologies: Advanced composite structure Hybrid-electric drive Electronics & software intensive control Efficient suspension, propulsion, and accessory technologies START FROM A CLEAN SHEET AND OPTIMIZE THE VEHICLE AS A SYSTEM Must consider complete production and overhead costs as well as cradle to grave costs to uncover practical solutions Then provide required energy in an efficient, clean, and cost-effective manner

5. creating the team

6. Unique Synthesis of Expertise Best practice aerospace systems-engineering Skunk Works breakthrough product development Right-the-first-time design practice

7. Unique Synthesis of Expertise Best practice aerospace systems-engineering Entrepreneurial spirit & motorsport heritage

8. Unique Synthesis of Expertise Best practice aerospace systems-engineering Rigor of high-volume auto industry Entrepreneurial spirit & motorsport heritage

9. creating the revolution

10. summary of the Revolution Breakthrough Performance Matches or beats conventional platforms in style, comfort, performance, and safety 99 mpg equivalent on gaseous Hydrogen fuel Zero emissions Cost competitive in a variety of variants near term or longer term It is desirable by any measure Platform-based design, illustrated by a mid-size crossover vehicle for Gen-X/Gen-Y drivers with active outdoor lifestyles Many performance parameters influenced by Fleet requirements Breakthrough Design & Manufacturing Flexible platform-based vehicle design Powerful onboard information network w/ fault tolerant power supply & distribution Brake, power, traction, and steer-by-wire controls Integrated aerodynamic design elements Low accessory, heating, and cooling loads Innovative vehicle assembly ideal for niche variants

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

14. vehicle information management and control: VIMaCS Central “nervous system” Customizable, plug-in electronics and seamless software-based upgrades Intuitive, easily customizable user interface Integrated intervention and distraction avoidance features and ergonomics Advanced on-board and remote diagnostics

15. vehicle dynamics All-wheel digital traction, stability, and braking Upper Wishbone Front Subframe Front Knuckle Lower Wishbone Rear Trailing Arm

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!