First image of production Chevrolet Volt

The lofty electrical range target of 40 miles that GM has set for the Chevrolet Volt is not an easy one for its engineers to reach. One way that they will get closer to it is through extensive wind tunnel testing to minimize drag.

According to GM Global Vehicle Line Executive and Global Vehicle Chief Engineer for the E-Flex System Frank Weber, the Volt's electric range is more sensitive to aerodynamic improvements rather than mass reduction, which typically plays a larger role in traditional cars. Aerodynamic drag accounts for about 20 percent of the energy consumed by an average vehicle.

According to GM Global Design honcho Ed Welburn, GM has already succeeded in cutting the production Volt's drag coefficient by 30 percent over that of the concept, with more tests and revisions planned to reduce it further. The Volt is still in an early stage of development, so all wind tunnel testing is being done on a 1/3 scale model that includes a detailed underbody and engine compartment and analysis is performed using computer models. A full-scale prototype is tested towards the end of the development cycle to validate the physical and mathematic scale model results.

The Volt will be the first vehicle developed at the new E-Flex Systems Design Studio located inside GM's Advanced Design Center in Warren, Michigan. It is headed by Volt Concept lead exterior designer Bob Boniface, who will supervise a team of 45 designers, engineers, sculptors, scientists and administrative staffers. Beyond the Volt, the studio will be responsible for developing other future vehicles based on the E-Flex platform that will underpin the Volt.