[cfg83]

Hello -

Got this in my e-mail from Aptera. I think this is an engineer (in charge of manufacturing?), David Oakley. I didn't bother with Paul Wilbur's statement :

Aptera's Beach Body (evolution of the 2-series composite body)

When I came on board a year ago, it was clear that the approach to composites was useful to produce the initial concept vehicles, but was inadequate for producing a vehicle at any scale. The two primary fronts included product development and process development, both of which required a substantial commitment of resources and time.

Product Development: The initial body design had the vehicle split top to bottom with a joint, which extended the entire length of the vehicle. As you can imagine, this was a major issue from both a manufacturability and warranty perspective. The problems resulting from this construction included:

1. Manufacturability: The butt joint, the resin, and the material choices made the ability to match components a major issue and would have severely limited production and product quality. The vehicles that could be produced with this scheme would have had substantially higher costs to achieve an acceptable finish due to seam treatment being in direct view of customer sight lines.

2. Warranty: The butt joint was placed directly in an expected impact zone, which meant even low speed crashes would result in the integrity of the body being severely compromised. Butt joints are weak and difficult to control for body alignment. The safety of the vehicle in side impact collisions would be substantially less than a body with properly designed and placed joints.

Process Development:

1. Manufacturability: The initial materials and processes used were suitable for demonstrating the powerful application of composites in a one-off mode, but were not adequate for high quality, cost effective manufacturing.

2. FMVSS Compliance: These same materials would not have passed the FMVSS standards for flammability.

The interest, excitement, and anticipation of the vehicle has caused many to speculate and over simplify the need for our re-design efforts, which is very understandable given how revolutionary a vehicle like ours will be. However, we could not move forward with those kinds of serious, identifiable, and solvable issues.

We only get one first impression as we deliver the promise while caring for the safety and confidence of our customers.

New bodyThe re-design of the body enabled us to resolve these issues from a structural standpoint while enabling us to develop potentially compelling alternative finish methods. These finish methods will require less capital and have less impact on the environment. That means a less expensive and more earth friendly composite body! The process re-design is something that we have not discussed publicly, but it too took the same type of time commitment to get right using best practice tools like Six Sigma. Both of these efforts were imperative if Aptera was to stay true to the dream of lightweight, aerodynamic, and safe vehicles. Had we cut the corner, we would have killed the world's most efficient EV. Having taken the time and effort, we insured its ability to flourish.

-David Oakley

CarloSW2