Structural VIPVPath to mass production
A development and industrialisation proposal from Savcor to Mercedes-Benz
Concept visualisation · S-Class
The integration opportunity
Energy-active body panels that keep the automotive finish.
Solar cells laminated inside structural body panels, beneath a coloured, coated surface designed to read as the vehicle's finish.
- Structure
The panel is the part, not an add-on module
- Surface
The PV recedes beneath the finish
- Production
A process and pilot line planned for series volumes
Proposed application areas · S-Class and Mercedes-Maybach
One structural PV technology, three applications.
- 01
Hood
Structural PV laminated within the hood, beneath a colour-matched finish.
- 02
Rear lid
The same construction applied to the rear lid, shown on the saloon trunk.
- 03
Interior PV shade
A PV surface for a shade moving across the panoramic-roof opening.
Supported by colour, material and finish development and a proposed pilot line: five costed programmes in total.
Prototype photographs
Built, not rendered.
Structural PV prototype parts already exist, including hood geometry. Finish and colour are still in development.
- HoodCurrent TRL 6
- Rear lidCurrent TRL 5
- Interior PV shadeCurrent TRL 3
Structural layer architecture
One laminated structure, six functional layers.
Savcor's proposed build-up on a double-curved panel: the solar pre-laminate sits between a coloured polymer skin and a thermoformable honeycomb sandwich with compressed, closed edges.
Preferred structural concept: thermoformed honeycomb. A glass-fibre or carbon-fibre composite construction is an alternative to be evaluated if required.
- 01
Coloured, coated polymer
Thermoformed or moulded · coated for durability
- 02
Encapsulant
- 03
Solar pre-laminate with IBC cells
Interdigitated back-contact cells
- 04
Encapsulant
- 05
Thermoformable honeycomb sandwich
Compressed, closed edges · inserts for hinges, latches and other components
- 06
Inner liner
Appearance, sound, fit and barrier functions
Proposed mass-production flow
Three component streams, one 3D lamination.
Component preparation
Integration
Finishing
Front plate
Solar
pre-laminate
Rear plate
01
Preprocess
02
Thermoforming
Cells · encapsulation · back sheet
03
Pre-lamination
04
Preprocess
05
Forming
06
3D lamination
On tool, autoclave crosslinking
07
Post-processing
08
Painting
09
Assembly
Proposed process from the Savcor production plan; not a validated factory design. Each stage includes quality checks: visual and dimensional inspection, with bond strength, EL (electroluminescence) and IV (current–voltage) measurement and function testing where relevant.
Manufacturing geography · planning assumption
Built in Stuttgart by Savcor.
The proposed arrangement: Savcor manufactures the parts in Stuttgart, with the Savcor solar pre-laminate supplied from Finland and other inputs sourced in Germany.
Final logistics will be agreed with Mercedes-Benz. Completion in Finland is also possible where it provides the best overall solution; Savcor will accommodate the required manufacturing and logistics footprint.
- Savcor Stuttgart locationStuttgart, DE
- Savcor solar pre-laminateFinland
- Front and rear platesGermany
- Encapsulation foilsGermany
- Paints and printsGermany
- ConnectorsGermany
- Inserts and edge finishGermany
01 · HOOD
Hood
The most advanced application, demonstrated with the prototype in a relevant environment.
TRL 6
Current status
TRL 7
Target after 10 months of development
TRL 8
Target within 18 months
Proposed targets for the technology; not qualification of the pictured vehicle.
Concept visualisation · S-Class
Concept visualisation · Mercedes-MaybachHood · development proposal
One production-geometry hood, developed and tested in parallel.
Development & tooling
Jan – Oct 2027
Actual production geometry · single hood · all tooling included
€350,000
Testing
Jan 2027 – Jun 2029
Staged test parts; complete by June 2029 at the latest
€560,000
€380,000 in 2027 · €180,000 in 2028
Hood total · estimate
€910,000
02 · REAR LID
Rear lid
The hood's structural architecture, developed in parallel and shown here on the saloon trunk lid.
TRL 5
Current status
TRL 7
Target after 12 months of development
TRL 8
Target within 20 months
Proposed targets, assuming development in parallel with the hood.
Concept visualisation · S-Class
Concept visualisation · Mercedes-MaybachRear lid · development proposal
One production-geometry rear lid, tested in parallel.
Budget based on the original tailgate scope; its application to the saloon trunk lid is a planning assumption.
Development & tooling
Jan – Dec 2027
Actual production geometry · single part · all tooling included
€380,000
Testing
Jan 2027 – Aug 2029
Staged test parts; complete by August 2029 at the latest
€450,000
€240,000 in 2027 · €210,000 in 2028
Rear lid total · estimate
€830,000
Hood & rear lid · test programme
Staged testing, from flat samples to production parts.
- Flat miniature samplesMonths 1–3
- Full-size flat samplesMonths 4–6
- Production-geometry partsFrom about month 6, as testing requires
| Allocated testing cost · EUR | 2027 | 2028 | Total | 2029 |
|---|---|---|---|---|
| Hood | 380,000 | 180,000 | 560,000 | To be confirmed |
| Rear lid | 240,000 | 210,000 | 450,000 | To be confirmed |
Testing starts in January 2027, in parallel with development. Costs are allocated for 2027 and 2028; any 2029 allocation is to be confirmed.
Budgeting assumption: 10 hood test parts and 10 trunk-lid test parts, with iterations included within the agreed development scope. Final sample allocation and iteration scope to be agreed.
03 · Interior PV shade · indicative panoramic-roof integration concept
Shade inside. Solar energy above.
A PV surface for an interior shade that moves across the panoramic-roof opening. Savcor proposes to develop the PV surface; the mechanical shade system is not part of this proposal.
- Scope
- PV-surface development
- Objective 2027
- An early-stage PV-surface prototype and its test protocol
- Maturity
- TRL 3 today; the target level is to be agreed
Development & tooling
€120,000
Test-protocol development
€54,000
Total · 2027
€174,000
04 · Colour, material & finish (CMF) · 2027
A finish in which the PV recedes.
Proposed for discussion with Mercedes-Benz Design: an almost invisible expression for the S-Class, and a more visible, refined one for Mercedes-Maybach.
- 01MaterialsCatalogue of materials · touch and feel
- 02ColoursCatalogue of colours · appearance versus power output
- 03Colour matchingTo the vehicle's painted body
- 04Graphic studiesSelected special effects, such as logos and graphics
Special effects optional; scope and pricing to be agreed separately.
05 · Pilot industrialisation · hood & rear lid
A proposed pilot line for hood and rear lid.
Greenfield equipment installation in an existing building: low-volume mass-production tools and lines.
Proposed Mercedes-Benz contribution
€4.5M
€4,500,000
Duration · planning assumption
~18
months; schedule placement to be confirmed
Capacity · planning assumption
20,000
units per year: 10,000 hoods plus 10,000 trunk lids · preliminary planning basis
Proposed production functions
- Forming, cutting & inserting
- Lamination
- Painting
- Assembly
Estimated staffing: 6 people per shift, subject to confirmation.
Active-layer price target · conditional, not a quotation
Following successful completion of the project, Savcor targets a mass-production price below €400/m² for the active layer with optimal geometry. Excludes paint and special assembly components, such as inserts.
Programme view · January 2027 – December 2029
Development in 2027, testing into 2029.
- First payment (provisional)
- Development
- Testing / test protocol
- Pilot industrialisation (indicative)
- Proposed TRL target
Indicative schedule. Testing is shown to the latest stated end dates; pilot placement and any 2029 allocation are to be confirmed. Programme commencement and timing depend on receipt of the agreed initial payment and confirmation of requirements.
Budget summary · estimate
Programme budget requirement.
€6,678,000
- Budget 2027€3,311,333
- Budget 2028€3,366,667
- 2029To be confirmed
Development and tooling fall in 2027; testing in 2027 and 2028. Testing continues into 2029; any 2029 allocation is to be confirmed.
| Programme | Development & tooling | Testing / test protocol | Total |
|---|---|---|---|
| Hood | 350,000 | 560,000 | 910,000 |
| Rear lid | 380,000 | 450,000 | 830,000 |
| Interior PV shade | 120,000 | 54,0001 | 174,000 |
| Subtotal | 850,000 | 1,064,000 | 1,914,000 |
| Colour, material & finish | – | – | 264,000 |
| Pilot industrialisation2 | – | – | 4,500,000 |
| Total | 6,678,000 |
- Test-protocol development.
- Proposed Mercedes-Benz contribution.
The proposal at a glance
One proposal, from prototype to pilot production.
Five costed programmes, each with its own maturity objective. Development is planned to commence in January 2027; pilot timing remains indicative.
Total budget requirement · estimate
€6,678,000
- Development & tooling€850,000
- Testing & test protocol€1,064,000
- Appearance and pilot€4,764,000
€3,311,333 in 2027 · €3,366,667 in 2028
- 01TRL 6 → 8 target€910,000
Hood
Production-geometry hood
Development €350,000 · Testing €560,000
- 02TRL 5 → 8 target€830,000
Rear lid
Production-geometry rear lid
Development €380,000 · Testing €450,000
- 03TRL 3 today€174,000
Interior PV shade
Early-stage PV-surface prototype
Development €120,000 · Test protocol €54,000
- 042027€264,000
Colour, material & finish
Proposed for discussion with Mercedes-Benz Design
- 05~18 months€4,500,000
Pilot industrialisation
Hood and rear lid
Intended outcome: mass-production-ready hood and trunk-lid solutions, and an informed technical basis for progressing the interior PV shade. This is a budgetary proposal: deliverables, sample allocation, tooling details and acceptance requirements will be confirmed once requirements and commercial terms are agreed.
Concept visualisation · Mercedes-MaybachFor discussion
From prototype to production, together.
- 01Application geometry and scopeHood, rear lid and interior PV shade on S-Class and Mercedes-Maybach
- 02Development and validationDevelopment, testing and maturity targets for 2027–2029
- 03Pilot and commercial frameworkPilot line, capacity and the proposed €4.5M contribution
Thank you.