Denso Corporation and Daihatsu have jointly developed a light, high-performance, front-end module that is 30% lighter than the conventional component structure for the latter’s light sports Copen model.

The new front-end module contains the carrier, radiator, electric fan and condenser for the car’s air conditioner, intercooler and air cleaner.

After delivery, Daihatsu will install the bumper and headlights on the Denso-manufactured front-end module.

The new carrier is made of a light, cost-efficient polypropylene (PP) material reinforced with long-fibre glass, which reduces weight and cost. The resin material used to build the carrier is also recyclable.

Traditionally, radiator and air-conditioner condenser products are attached to the front of the vehicle, where they are exposed to the air while in operation for heat exchange efficiency.

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By optimising the entire front-end thermal component zone, improved heat exchange efficiency not possible through improvements on individual components was achieved.

Denso began producing cooling modules in August 2000 and air intake modules in September 2001 and, since then, has completed development of cockpit modules.

New materials and design led to a 30% weight reduction for high performance.