Bonded aluminium monocoque
Unlike competitors built from conventional steel, LEVC products are built upon an anodised aluminium monocoque.
The aluminium components are glued together using an incredibly strong hot cure adhesive. The glue remains dormant until the entire structure is baked in an oven at 180°C for 20 minutes. Once cured, the adhesive becomes rock solid, turning the frame into a single, remarkably rigid structure.
This bonding process improves the vehicle’s strength, returning joints which are cohesive and well connected across the whole of the joint, rather than at single points.
The resulting bonds are more than twice as strong as traditional welding. In this test the upper welded joint failed at a load of 16kN, whereas the bonded joint remained strong until 34kN (3.4 tons).
Weighing just 370 kg, the body structure effectively combines high torsional rigidity with lightweight construction.
Around 30% lighter than an equivalent steel structure, this delivers a crucial weight saving over a conventional steel body and frame.
Sheet Moulded Composite exterior
Another first for the commercial vehicle sector, LEVC products are made from a tough SMC material which is lighter, more flexible and more resilient to light dents and knocks.
The high strength of the external structure means the damage to internal components is less likely in the event of an impact.
Quicker & easier to repair
LEVC products are designed to resist damage, and be quick and easy repaired in order to minimise down time off the road.
Reference points are located in all of the key body structures. In the event of an impact, a portable measurement system can quickly verify whether damage is purely cosmetic and whether the underlying structure has been compromised.
If damage does occur, the most vulnerable panels such as the bumpers and rear quarter panels are attached by bolts, meaning they can be quickly and easily replaced, and the SMC panels can repaired more quickly.