Why Sustainability Matters in Automotive Manufacturing

The automotive industry plays a crucial role in shaping a sustainable feature. As vehicle manufacturers seek to reduce carbon emissions and improve fuel efficiency, selecting the right materials and manufacturing processes is more important than ever. At Shape, we are committed to innovation that enhances sustainability. Our advanced roll forming process is a key enabler of lightweight, high-strength designs that significantly reduce CO2 emissions throughout a vehicle’s lifecycle.

The Environmental Impact of Roll Forming vs. Cold Stamping

By utilizing roll forming instead of cold stamping, we achieve significant CO2 savings in two key areas:

  • Manufacturing Phase – Reduced material waste and energy-efficient processing lead to lower CO2 emissions
  • Use Phase – Lighter-weight components improve vehicle fuel efficiency, reducing CO2 emissions over the vehicle’s lifetime.

How Do We Calculate the Sustainability Benefits?

Our sustainability study is based on industry-validated assumptions and real world manufacturing data.

Key Assumptions & Inputs:

  • Vehicle Weight (2022 Average): 1,860.91kg (4,094 lbs) (EPA)
  • Vehicle Lifetime: 150,000 miles
  • Fuel Efficiency Impact: 0.4% savings per 1kg mass reduction for internal combustion engine (ICE) vehicles
  • CO2 Emissions Per Vehicle Per Year: 4,600 kg (EPA)
  • CO2 Absorption Per Tree Per Year: 21.77 kg (8billiontrees.com)
  • Energy Consumption Data: Based on Shape Corp. manufacturing measurements and local energy conversion rates (Grand Haven, MI – Foresight Management)

CO2 Savings with Roll Forming

By switching from cold stamping to roll forming, we significantly cut CO2 emissions in automotive production and use.

Manufacturing Phase Savings

  • CO2 Reduction per Bumper: 7.63 kg
  • Annual Vehicle Production: 200,000 vehicles
  • Vehicle Program Life: 7 years
  • Total Manufacturing CO2 Savings:
    • 10,682,000 kg CO2 saved over the full program

Use Phase Savings

  • Mass Savings per Bumper: 0.95 kg
  • CO2 Reduction per Vehicle Over Lifetime: 11.36 kg
  • Total Use-Phase CO2 Savings:
    • 15,904,000 kg CO2 saved over the full program

Total CO2 Reduction

  • 26,586,000 kg CO2 saved by choosing roll forming over cold stamping

What Does This Mean?

  • Equivalent to the annual carbon absorption of 1,221,000 trees
  • Annual CO2 savings comparable to removing emissions from 825 internal combustion engine (ICE) vehicles

Sustainable Innovation for the Future

Shape Corp. is committed to leading sustainable advancements in manufacturing. By choosing roll forming over cold stamping, we are helping our customers achieve lighter, more efficient, and environmentally friendly vehicles.

For further details on our CO2 savings calculations and sustainability initiatives, please contact us