Designed to showcase affordable, environmentally-friendly technologies, the Eco Elise project focused on the use of sustainable materials and cleaner manufacturing processes, weight reduction, as well as renewable energy generation, reducing carbon miles and efficient driving techniques
Hemp fabrics have been used as the main constituent in the Class A composite body panels and spoiler. The hemp is used with a polyester resin to form a hybrid composite, but Lotus hopes that a fully recyclable composite resin will be viable in the near future.
Hemp fibres have also been used in the manufacture of the lightweight seats and they are upholstered in a biodegradable woollen fabric which is ethically produced and does not use any dyes. Sisal has been used for the carpets.
In partnership with DuPont, Lotus has developed a water-based paint system which includes primer, colour coat and lacquer. It is reported to be the first time that it has been possible to hand spray a water-based Class A production paint finish. Using this water-based technology, Lotus is able to achieve savings in energy consumption (a result of the low cure temperature of the paint) and a reduction in solvent emissions.
The hemp hard top roof of the Eco Elise incorporates two flexible solar panels. These contribute power to the electrical systems. This application shows the installation of solar panels into a composite Class A panel with a double curvature. Using this technology on a greater number of panels would make it possible to provide more power, especially on a larger vehicle.
The hemp fibres have been farmed in East Anglia, thus reducing the carbon miles incurred in the production of this Elise. Lotus has component manufacturing facilities and a paint facility at its headquarters in Hethel, Norfolk, with another manufacturing site a short distance away in Norwich. The company operates a carefully managed logistics system operating between sites to improve efficiency, reduce costs and carbon miles. This is a Kanban driven barcode system that has been adopted by key suppliers. The process also uses packaging that is recycled many times over to eliminate waste.
Weight reduction measures in all areas, ranging from the wheels to the stereo system, have resulted in a total saving of around 32 kg (70.5 lbs) in the Eco Elise over the Elise S, which reduces the fuel required to drive the car.