UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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Nearly half of ULSAB’s mass consists of parts that require tailored
blanks, which enable the design engineer to locate various steels
within the part precisely where their attributes are most needed,
thereby removing mass that does not contribute to performance.
Tailored blank usage (shaded)
ULSAB also features a hydroformed side roof rail, which provides
an essential load path for structural performance and crash energy
management from the top of the ‘A’ pillar along the roof, into the
‘B’ and ‘C’ pillars and into the rear of the structure. In addition to
tubular hydroforming, ULSAB uses sheet hydroforming for the roof
panel. The work hardening effect produces improved dent
resistance in the formed part, especially in the center of the panel.
ULSAB Final Report