Case Study: Lotus.....
Brief

Develop roof systems for new Lotus Elise and Vauxhall Opel VX220

Soft top customer requirement:

Where possible to use carry-over features developed and produced on VX220 soft top development.
The final design should still encompass the “ bat wing ” identity of the original Elise.
No tools to be needed for fitting or removal.
Time for fitting and removal to be 1 minute (previous model takes 15 – 20 minutes).

Hard top customer requirement

Improve ingress / egress for passenger & driver.
If panels are removable they need to be stowed within the vehicle.
Single handed operation required by user.
Lightweight construction.

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Solution.....

Soft top:

Front end mechanism used design developed on VX220.
Rear end mechanism used same philosophy as VX220, but modified.
Transverse tensioning method used combination of VX220 and fixed rear cable.
Additional roof strut tensioning front to rear developing using “Plytron” composite technology used previously on Nissan reversible floor.
Fit/Removal: 55 seconds.

Hard top:

Easy access was established by creating hinged panels with single-handed operation.
These panels also had the option of removal and stowage in the boot still leaving sufficient room for a soft weekend holdall.
Panel material construction being reviewed in GRP and Carbon Fibre for the racing option.

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Conclusion.....

This was a unique challenge for Labyrinth Developments. Working as a small team within a larger innovative company. We established a name for concept development, offering innovative ideas and practical production solutions in record time scales.

The nature of the design was such that patents have been developed for Lotus Cars for soft and hard top Elise and soft top Vauxhall/Opel VX220. On successful completion these worldwide patents have now been assigned from Labyrinth to Lotus Cars.

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