Chapeau! Aluminum Top Hat Offers Lighter Alternative

Alumobility’s latest technical study takes on the Top Hat to demonstrate weight savings that meet or exceed the performance of the steel reference in an Audi e-tron® electric SUV.

Presented at the 2021 EuroCarBody conference, Alumobility suggests an approach to the vehicle’s Top Hat that leverages a range of aluminum alloys to replace AHSS and UHSS. The aluminum Top Hat in the study utilizes the latest forming and joining technology to reduce the number of parts and joints leading to significant weight savings while meeting or exceeding performance attributes for various load cases.


  • 42% weight savings
  • Number of parts and joints reduced
  • Performance attributes met or exceeded for various load cases

For a preview of the study, download the PDF.

Download PDF

For more info on the Top Hat Study, or to connect with our technical team on the details, please complete the form below.


NOTE: Alumobility does not engage in any joint R&D regarding aluminum ABS products/production technology or related product development or any other R&D seeking intellectual property rights protection; standard setting activities, including future aluminum ABS products; joint commercialization or marketing activities of aluminum ABS products; cooperation of aluminum ABS suppliers on actual, ongoing or future bids for automotive platforms. These activities are the domain of individual member companies at their own discretion.