HONDA Insight - Manual (Page 25)

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On the Insight, each frame member's size and strength is optimized so that the frame is strong where it
needs to be, and lighter in less critical areas. A variety of shapes are used, including hexagons, ovals, H-
sections and reinforced box-sections. The door and windshield pillars, front and rear side-frame members,
lower body sills, cross members and floor frame members are all formed in this manner.
In more highly loaded areas of the body (such as the front and rear sub frames), larger, internally
ribbed, hexagonal aluminum frame members are used. These are joined to other frame members via rigid,
die-cast aluminum joints. Die-castings are also used at engine and suspension mounting points. These die-
castings offer versatility and cost savings, because they can be designed to suit specific size, space and
strength requirements.
Thixotropic Die Casting
Some of the die-cast joints used in the Insight's aluminum body are made using a newly developed
casting technology invented by Honda engineers, called Thixotropic Die Casting. Thixotropic Die Casting
uses aluminum alloy that has been heated to a semi-solid condition, instead of the molten, liquid state
normally used in die casting. Pieces made with molten aluminum must be more highly processed and
refined before casting; however, Thixotropic Die Casting requires less energy for smelting (an important
consideration since aluminum is more expensive than steel), and owes much of its strength to the controlled
formation of discrete aluminum crystals within the metal casting.
Safety
The Insight was designed to meet or exceed the latest U.S., European and Japanese safety standards.
The interior is designed to meet the 2003 safety standards for side-impact and head-injury protection.
The Insight's aluminum body and frame are designed to meet the safety and impact-protection
standards Honda engineers set for it. At the heart of this design is a newly developed
Honda technology called G-Force Control Technology, or G-CON. G-CON
optimizes each part of the Insight's aluminum body and frame to best absorb a
specific type of impact. The cabin floor, for example, forms a strong and rigid
foundation, designed to minimize deformation in an impact. Outside of this area, the surrounding aluminum
frame members have been tailored to control impact forces.
Full-frontal and offset-frontal impacts are first absorbed by the large-section,
hexagonal extrusions that serve as the front-side frame members. These hexagonal
sections are made up of six individual equilateral triangles and are designed to
progressively collapse like the bellows of an accordion in an impact. A die-cast
aluminum joint connected to the rear of these extrusions transfers any additional
impact energy rearward to an oval-shaped, curved hexagonal extrusion, which
further absorbs energy by bending upward.
The aluminum extrusions that extend from the passenger compartment all the
way back to the rear of the Insight on either side are also designed to progressively
absorb rear-impact energy. In addition, the spare tire and wheel, and the Insight's
aluminum suspension, including the tires and wheels, are designed to aid in rear-
impact energy absorption.
See also:
• Restraint System
• Body Panels