Method for producing a vehicle body

Abstract

The present disclosure provides a method for producing a vehicle body. A method of manufacturing a vehicle body includes: (i) casting an automotive support structure defining a front body structure and a rear underbody structure; (ii) physically detaching the vehicle support structure to detach the front body structure from the rear underbody structure; (iii) fixing the front body structure to the sill panel along a front end of the sill panel after the splitting; and (iv) securing the rear underbody structure to the sill panel along a rear end of the sill panel after the splitting such that the front body structure is spaced apart from the rear underbody structure via the sill panel.

Description

Technical Field

[0001] The present disclosure relates to vehicle body components and methods of manufacturing vehicle body components. Background Art

[0002] Vehicles and automobiles include a body and / or frame that serves as the underlying support structure for other subsystems of the vehicle (eg, powertrain, steering system, etc.). Summary of the Invention

[0003] A method of manufacturing a vehicle body comprises: (i) casting a vehicle support structure; (ii) physically splitting the vehicle support structure to define a front vehicle body structure and a rear underbody structure; (iii) directly securing the front vehicle body structure to one or more additional vehicle body subassemblies; and (iv) directly securing the rear underbody structure to the one or more additional vehicle body subassemblies. When the rear underbody structure is secured to the one or more additional vehicle body subassemblies, the front vehicle body structure, the rear underbody structure, and the one or more additional vehicle body subassemblies form the vehicle body. When the rear underbody structure is secured to the one or more additional vehicle body subassemblies, at least some of the one or more additional vehicle body subassemblies are positioned between the front vehicle body structure and the rear underbody structure. The front vehicle body structure and the rear underbody structure are spaced apart from each other within the formed vehicle body.

[0004] A method for manufacturing a vehicle body comprises: (i) casting a vehicle support structure, the vehicle support structure defining a front body structure and a rear underbody structure; (ii) physically splitting the vehicle support structure to remove the front body structure from the rear underbody structure; (iii) securing the front body structure to the rocker panel along a front end of the rocker panel after the splitting; and (iv) securing the rear underbody structure to the rocker panel along a rear end of the rocker panel after the splitting, such that the front body structure is spaced apart from the rear underbody structure via the rocker panel.

[0005] A method of manufacturing a vehicle body includes: (i) casting a front vehicle body structure and a rear underbody structure into a first integrated structure; (ii) cutting the first integrated structure to separate the front vehicle body structure from the rear underbody structure; (iii) securing the front vehicle body structure to a first region of a pair of opposing rocker rails; and (iv) securing the rear underbody structure to a second region of the pair of opposing rocker rails, such that the front vehicle body structure, the rear underbody structure, and the pair of opposing rocker rails form a second integrated structure. The front vehicle body structure and the rear underbody structure are spaced apart from each other within the second integrated structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a side view of a central portion (e.g., a vehicle bed portion) and a rear portion (e.g., a luggage compartment portion) of a vehicle body structure;

[0007] Figure 2 is a perspective view of a front body structure forming a front portion of the body structure;

[0008] Figure 3 is a perspective view of a rear underbody structure partially forming a rear portion of the vehicle body structure;

[0009] Figure 4 is a perspective view of a lower portion or understructure of a vehicle body including a front vehicle body structure and a rear underbody structure;

[0010] Figure 5 is a schematic diagram illustrating a process for forming a front vehicle body structure and a rear underbody structure; and

[0011] Figure 6 is a flow chart illustrating a method for forming a vehicle body structure. DETAILED DESCRIPTION

[0012] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of particular components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to employ the embodiments in different ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the accompanying drawings may be combined with features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0013] refer to Figure 1 , a side view of a portion of a vehicle body structure 10 is shown. The vehicle body structure 10 may be referred to simply as a vehicle body. The vehicle body structure 10 may include roof rails 12, A-pillars 14, B-pillars 16, C-pillars 18, D-pillars 20, rocker panels 22, A-pillar tower reinforcements 24, cross members, floor members, floor panels, or any other component or subcomponent of the vehicle body structure. Components or subcomponents of the vehicle body structure 10 may form front door frames 26 and rear door frames 28. Figure 1The images in FIG. 1 show common vehicle body components or subcomponents. The specific shape and structure of vehicle body 10 are not intended to be limiting. Other vehicle body structure configurations should be construed as encompassed herein. For example, some vehicle body structures may not include D-pillars 20 or may not include rear door frames 28.

[0014] The subcomponents of the vehicle body structure 10 may be secured to one another via fasteners (e.g., screws, rivets, bolts, etc.), adhesives, welding, or any other method known in the art. The subcomponents of the vehicle body structure 10 may be made of steel, aluminum, magnesium, titanium, or any other material that may serve as a support structure for other components and subsystems of the vehicle.

[0015] refer to Figure 2 and Figure 5 , respectively showing a perspective view of a front portion of a vehicle body structure (e.g., vehicle body structure 10) or a front vehicle body structure 30 and a schematic diagram showing a process for forming the front vehicle body structure 30 together with a rear underbody structure 32. The front vehicle body structure 30 and the rear underbody structure 32 are Figure 5 Shown in bottom view.

[0016] The front body structure 30 may include first and second opposing inner front longitudinal beams 34. The first and second opposing inner front longitudinal beams 34 may also be referred to as a pair of front longitudinal beams 34. The inner front longitudinal beams 34 partially form the front body structure 30. The inner front longitudinal beams 34 define an engine compartment 36 therebetween. More specifically, the inner front longitudinal beams 34 may define opposing sides of the engine compartment 36. The engine compartment 36 is a space configured to receive an engine or other power source (e.g., an electric motor) of a vehicle including the front body structure 30. The front body structure 30 may also include a cross member 38 extending between the inner front longitudinal beams 34. The cross member 38 also partially forms the front body structure 30. The cross member 38 may partially define the engine compartment 36. More specifically, the cross member 38 may define a rear portion or back portion of the engine compartment 36.

[0017] The front body structure 30 may also include first and second outer spear-type structural rails 40. The first and second outer spear-type structural rails 40 may also be referred to as a pair of spear-type structural rails 40. The outer spear-type structural rails 40 also partially form the front body structure 30. The first outer spear-type structural rail 40 is disposed laterally outward from the first inner front longitudinal rail 34 relative to the engine compartment 36, while the second outer spear-type structural rail 40 is disposed laterally outward from the second inner front longitudinal rail 34 relative to the engine compartment 36.

[0018] The front body structure 30 may also include first and second wheel well panels 42 defining a wheel well 44 configured to receive a wheel of a vehicle including the front body structure 30. The first and second wheel well panels 42 may also be referred to as a pair of wheel well panels 42. The first wheel well panel 42 is disposed between the first inner longitudinal rail 34 and the first outer gun-type structural rail 40. The second wheel well panel 42 is disposed between the second inner longitudinal rail 34 and the second outer gun-type structural rail 40. The first and second wheel well panels 42 define first and second openings 46 configured to receive a shock absorber or strut tower 48 (e.g., Figure 4 The first opening 46 is provided between the first inner longitudinal beam 34 and the first outer gun-type structural longitudinal beam 40 . The second opening 46 is provided between the second inner longitudinal beam 34 and the second outer gun-type structural longitudinal beam 40 .

[0019] refer to Figure 3 and Figure 5 , respectively showing a perspective view of a rear underbody structure 32 of a vehicle body structure (eg, vehicle body structure 10 ) and a schematic diagram illustrating a process for forming the front vehicle body structure 30 together with the rear underbody structure 32 .

[0020] The rear underbody structure 32 may include first and second opposing rear side beams or members 50. The first and second opposing rear side beams or members 50 may also be referred to as a pair of rear side beams or members 50. The first and second opposing rear side members 50 partially form the rear underbody structure 32. The first and second opposing rear side members 50 partially define first and second wheel wells 52, respectively. The rear underbody structure 32 may also include at least one cross member 54 extending between the first and second opposing rear side members 50. The at least one cross member 54 also partially forms the rear underbody structure 32.

[0021] refer to Figure 4 , a lower portion 56 of a vehicle body structure (e.g., vehicle body structure 10) is shown. The lower portion 56 of the vehicle body structure includes the front vehicle body structure 30 and the rear underbody structure 32 along with additional vehicle body subassemblies that form the vehicle body, or more specifically, the lower portion 56 of the vehicle body. The additional vehicle body subassemblies may include first and second strut towers 48, first and second rocker rails or rocker panels 58, and a luggage compartment support structure 60. The first and second strut towers 48 may also be referred to as a pair of strut towers 48. The first and second rocker rails or rocker panels 58 may also be referred to as a pair of rocker rails or rocker panels 58. Each of the first and second strut towers 48 may be secured to the front vehicle body structure 30. The first and second strut towers 48 may be disposed within the first and second openings 46, respectively.

[0022] The front body structure 30 can be secured to the additional body subassembly, or more specifically, to the first and second rocker panels 58, along the front ends 62 of the first and second rocker panels 58. More specifically, the rearwardly outward ends of the first and second inner front side members 34 can be secured to the front ends 62 of the first and second rocker panels 58. The rear underbody structure 32 can be secured to the additional body subassembly, or more specifically, to the first and second rocker panels 58, along the rear ends 64 of the first and second rocker panels 58. More specifically, the front ends of the first and second oppositely rear side members 50 can be secured to the rear ends 64 of the first and second rocker panels 58.

[0023] A cabin space 66 may be defined between the front body structure 30, the rear underbody structure 32, and the first and second rocker panels 58. A bulkhead 68 may extend between the rear ends 64 of the first and second rocker panels 58. The bulkhead 68 may be disposed above a forward cross member of the at least one cross member 54.

[0024] The trunk support structure 60 includes first and second rear side members 70, a trunk floor support 72, and a rear support member or bumper support 74. The first and second rear side members 70 may also be referred to as a pair of rear side members 70. The front ends of the first and second rear side members 70 may be secured to the rear ends of the first and second opposing rear side members 50, respectively. The bumper support 74 may extend between the rear ends of the first and second rear side members 70 and may be secured to the rear ends of the first and second rear side members 50. The trunk floor support 72 may be disposed between the first and second rear side members 70. The trunk floor support 72 may extend between the rearward-facing cross member of the at least one cross member 54 and the bumper support 74. The trunk floor support 72 may be secured to each of the rearward-facing cross member of the at least one cross member 54 and the bumper support 74.

[0025] The subcomponents of the lower portion 56 of the vehicle body structure may be secured to one another via fasteners (e.g., screws, rivets, bolts, etc.), adhesives, welding, or any other method known in the art. The subcomponents of the lower portion 56 of the vehicle body structure may be made of steel, aluminum, magnesium, titanium, or any other material that may serve as a support structure for other components and subsystems of the vehicle.

[0026] refer to Figure 5, a schematic diagram of a process for forming the front body structure 30 and the rear underbody structure 32 is shown. The process includes first casting a vehicle support structure 76. The vehicle support structure 76 is then physically separated along cut lines 78, which defines or forms the front body structure 30 and the rear underbody structure 32. The front body structure 30 and the rear underbody structure 32 may also exist or be defined within the vehicle support structure 76 after the casting process. The vehicle support structure 76 may be referred to as a first unified or integrated structure that includes or encompasses the front body structure 30 and the rear underbody structure 32.

[0027] refer to Figure 6 , a flow chart of a method 100 for forming a vehicle body structure (e.g., vehicle body structure 10), or more specifically, forming a lower portion 56 of a vehicle body structure, is shown. The method 100 begins at block 102, where the vehicle support structure 76 is cast. The casting process may include pouring molten material into a mold and then allowing the molten material to solidify to form the vehicle support structure 76. At block 102, the vehicle support structure 76 may define a front vehicle body structure 30 and a rear underbody structure 32. In other words, at block 102, the front vehicle body structure 30 and the rear underbody structure 32 may be cast as a first integrated structure.

[0028] The cast vehicle support structure 76 may include: (i) forming first and second opposing inner longitudinal rails 34, (ii) forming a cross member 38 extending between the first and second opposing inner longitudinal rails 34, (iii) forming first and second opposing outer gun-type structural rails 40, (iv) forming first and second wheelhouse panels 42, (v) defining first and second openings 46, (vi) forming first and second opposing rear side members 50, and (vii) forming at least one cross member 54 extending between the first and second opposing rear side members 50.

[0029] The method 100 then proceeds to block 104, where the vehicle support structure 76 is physically separated to define or form the front body structure 30 and the rear underbody structure 32 (e.g., by cutting the vehicle support structure 76 along cut lines 78). The front body structure 30 and the rear underbody structure 32 may be defined within the vehicle support structure 76. Thus, physically separating the vehicle support structure 76 at block 104 may include separating or cutting the vehicle support structure 76 (or a first integrated structure including the front body structure 30 and the rear underbody structure 32) to detach or separate the front body structure 30 and the rear underbody structure 32 from each other. The vehicle support structure 76 may be physically separated during a decasting process, where excess material is removed from the vehicle support structure 76 after the casting process.

[0030] Next, the method 104 proceeds to block 106 where the front body structure 30 is secured directly to one or more additional body components (eg, Figure 4 More specifically, the front body structure 30 may be secured to the first region of the first and second rocker panels 58. The first region of the first and second rocker panels 58 may correspond to the front ends 62 of the first and second rocker panels 58. The front body structure 30 may be secured to the first region of the first and second rocker panels 58. Figure 4 The front ends 62 are secured to the first and second rocker panels 58 in the same manner as described and shown.

[0031] The method then proceeds to block 108 where the rear underbody structure 32 is secured directly to one or more additional body components (e.g., Figure 4 More specifically, the rear underbody structure 32 may be secured to the second regions of the first and second rocker panels 58. The second regions of the first and second rocker panels 58 may correspond to the rear ends 64 of the first and second rocker panels 58. Figure 4 106. The first and second rocker panels 58 are secured to the rear ends 64 of the first and second rocker panels 58 in the same manner as described and shown. Note that the temporal order of blocks 106 and 108 can be altered so that block 108 occurs before block 106. Note also that the steps in blocks 106 and 108 can occur simultaneously.

[0032] According to the steps in blocks 106 and 108, the front body structure 30 and the rear underbody structure 32 are secured to one or more additional body components (e.g., the first and second rocker panels 58) such that: (i) the body structure 30, the rear underbody structure 32, and the one or more additional body subcomponents form a body (e.g., the body structure 10) or a portion of a body (e.g., the lower portion 56 of the body structure), (ii) at least some of the one or more additional body subcomponents (e.g., the first and second rocker panels 58) are positioned between the front body structure 30 and the rear underbody structure 32, and (iii) the front body structure 30 and the rear underbody structure 32 are spaced apart from one another within the formed body or the formed portion of the body. More specifically, the front body structure 30 and the rear underbody structure 32 may be spaced apart from one another within the formed body or the formed portion of the body via the first and second rocker panels 58. Once the front body structure 30 , rear underbody structure 32 , and one or more additional body components are secured to one another at frames 106 and 108 , the front body structure 30 , rear underbody structure 32 , and one or more additional body components may be referred to as a second unified or integrated structure.

[0033] although Figure 6 The steps shown in the boxes can generally be performed in chronological order, but it should be understood that Figure 6 The flowchart in FIG is for illustration purposes only, and the method 100 should not be construed as limiting Figure 6 Some steps of method 100 may be rearranged, while other steps may be omitted entirely.

[0034] Current production involves the use of front structural castings and rear underbody castings. These castings have replaced assemblies that typically consisted of many separate stampings, extrusions, or small castings that were then joined in a multi-stage process. Consolidating these parts into a single cast component eliminates the assembly process and the associated expense and capital tied up in assembly tooling. While this consolidation saves costs overall, it can require a significant investment in each die casting machine, as multiple die casting machines may be needed to support production volume.

[0035] The system disclosed herein encompasses a proposed manufacturing process in which the front structural casting and the rear underbody casting are cast together in a single die casting machine. During the de-casting process, which typically removes the runner system from the part, the front underbody and rear underbody are separated. Combining the front and rear underbody castings into a single tool requires a slightly larger press size than casting the front and rear underbody castings separately. However, the reduced cost of halving the total number of molds more than offsets the investment required for the larger press.

[0036] It should be understood that the first, second, third, fourth, etc. designations for any components, states, or conditions described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Further, it should be understood that any components, states, or conditions described herein without a numerical designation may be given a first, second, third, fourth, etc. designation in the claims if one or more of the particular components, states, or conditions are claimed.

[0037] The words used in the specification are descriptive and not restrictive, and it will be understood that various changes may be made without departing from the spirit and scope of the present disclosure. As previously mentioned, features of the various embodiments may be combined to form additional embodiments that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, it will be recognized by those skilled in the art that one or more features or characteristics may be compromised to achieve the desired overall system properties, depending on the specific application and implementation. Thus, embodiments that are described as being less desirable than other embodiments or prior art implementations with respect to one or more characteristics are within the scope of the present disclosure and may be desirable for a particular application.

[0038] According to the present invention, a method of manufacturing a vehicle body includes: casting a vehicle support structure; physically splitting the vehicle support structure to define a front vehicle body structure and a rear underbody structure; directly securing the front vehicle body structure to one or more additional vehicle body subcomponents; and directly securing the rear underbody structure to the one or more additional vehicle body subcomponents such that (i) the front vehicle body structure, the rear underbody structure, and the one or more additional vehicle body subcomponents form the vehicle body, (ii) at least some of the one or more additional vehicle body subcomponents are positioned between the front vehicle body structure and the rear underbody structure, and (iii) the front vehicle body structure and the rear underbody structure are spaced apart from each other within the formed vehicle body.

[0039] In one aspect of the present invention, physically separating the vehicle support structure to define the front underbody structure and the rear underbody structure includes cutting the vehicle support structure.

[0040] In one aspect of the present invention, the one or more additional vehicle body subcomponents include first and second rocker panels.

[0041] In one aspect of the invention, (i) the front body structure is secured to the one or more additional body subcomponents along front ends of the first and second rocker panels, and (ii) the rear underbody structure is secured to the one or more additional body subcomponents along rear ends of the first and second rocker panels.

[0042] In one aspect of the invention, (i) casting the automotive support structure includes forming first and second opposing inner longitudinal beams that partially form the front body structure, and (ii) the first and second opposing inner longitudinal beams define an engine compartment therebetween.

[0043] In one aspect of the present invention, casting the vehicle support structure includes forming a cross member extending between the first and second opposing inner longitudinal beams.

[0044] In one aspect of the invention, (i) casting the vehicle support structure includes forming first and second opposing outer gunmetal longitudinal rails that partially form the front body structure, (ii) the first outer gunmetal longitudinal rail is disposed laterally outward from the first inner longitudinal rail relative to the engine compartment, and (iii) the second outer gunmetal longitudinal rail is disposed laterally outward from the second inner longitudinal rail relative to the engine compartment.

[0045] In one aspect of the present invention, (i) casting the automotive support structure includes defining first and second openings configured to receive a strut tower along the front vehicle body structure, (ii) the first opening is disposed between the first outer gun-type structural rail and the first inner rail, and (iii) the second opening is disposed between the second outer gun-type structural rail and the second inner rail.

[0046] In one aspect of the invention, (i) casting the automotive support structure includes forming first and second opposing rear side members that partially form the rear underbody structure, and (ii) the first and second opposing rear side members partially define first and second wheel wells.

[0047] In one aspect of the present invention, casting the automotive support structure includes forming at least one cross member extending between the first and second opposing rear side members.

[0048] According to the present invention, a method of manufacturing a vehicle body includes: casting an automobile support structure, the automobile support structure defining a front body structure and a rear underbody structure; physically splitting the automobile support structure to remove the front body structure from the rear underbody structure; securing the front body structure to the rocker panel along a front end thereof after the splitting; and securing the rear underbody structure to the rocker panel along a rear end thereof after the splitting, such that the front body structure is spaced apart from the rear underbody structure via the rocker panel.

[0049] In one aspect of the present invention, physically disassembling the vehicle support structure to remove the front underbody structure from the rear underbody structure includes cutting the vehicle support structure.

[0050] In one aspect of the invention, (i) casting the automotive support structure includes forming first and second opposing inner longitudinal beams that partially form the front body structure, and (ii) the first and second opposing inner longitudinal beams define an engine compartment therebetween.

[0051] In one aspect of the present invention, casting the vehicle support structure includes forming a cross member extending between the first and second opposing inner longitudinal beams.

[0052] In one aspect of the invention, (i) casting the vehicle support structure includes forming first and second opposing outer gunmetal longitudinal rails that partially form the front body structure, (ii) the first outer gunmetal longitudinal rail is disposed laterally outward from the first inner longitudinal rail relative to the engine compartment, and (iii) the second outer gunmetal longitudinal rail is disposed laterally outward from the second inner longitudinal rail relative to the engine compartment.

[0053] In one aspect of the present invention, (i) casting the automotive support structure includes defining first and second openings configured to receive a strut tower along the front vehicle body structure, (ii) the first opening is disposed between the first outer gun-type structural rail and the first inner rail, and (iii) the second opening is disposed between the second outer gun-type structural rail and the second inner rail.

[0054] In one aspect of the invention, (i) casting the automotive support structure includes forming first and second opposing rear side members that partially form the rear underbody structure.

[0055] In one aspect of the present invention, the first and second opposing rear side members partially define first and second wheel wells.

[0056] In one aspect of the present invention, casting the automotive support structure includes forming at least one cross member extending between the first and second opposing rear side members.

[0057] According to the present invention, a method for manufacturing a vehicle body includes: casting a front vehicle body structure and a rear vehicle body bottom structure into a first integrated structure; cutting the first integrated structure to separate the front vehicle body structure from the rear vehicle body bottom structure; fixing the front vehicle body structure to a first area of ​​a pair of opposing side sill longitudinal beams; and fixing the rear vehicle body bottom structure to a second area of ​​the pair of opposing side sill longitudinal beams, so that the front vehicle body structure, the rear vehicle body bottom structure and the pair of opposing side sill longitudinal beams form a second integrated structure, wherein the front vehicle body structure and the rear vehicle body bottom structure are spaced apart from each other within the second integrated structure.

Claims

1. A method for manufacturing a vehicle body, comprising: Casting automotive support structures; physically splitting the vehicle support structure to define a front body structure and a rear underbody structure; securing the front body structure directly to one or more additional body subassemblies; as well as The rear underbody structure is directly secured to the one or more additional body subassemblies such that (i) the front body structure, the rear underbody structure, and the one or more additional body subassemblies form the body, (ii) at least some of the one or more additional body subassemblies are positioned between the front body structure and the rear underbody structure, and (iii) the front body structure and the rear underbody structure are spaced apart from one another within the formed body. 2 . The method of claim 1 , wherein physically separating the vehicle support structure to define the front underbody structure and the rear underbody structure comprises cutting the vehicle support structure. 3 . The method of claim 1 , wherein the one or more additional vehicle body subcomponents include first and second rocker panels.

4. The method of claim 3 , wherein (i) the front body structure is secured to the one or more additional body subcomponents along front ends of the first and second rocker panels, and (ii) the rear underbody structure is secured to the one or more additional body subcomponents along rear ends of the first and second rocker panels.

5. The method of claim 1 , wherein (i) casting the automotive support structure includes forming first and second opposing inner longitudinal beams that partially form the front body structure, and (ii) the first and second opposing inner longitudinal beams define an engine compartment therebetween.

6. The method of claim 5, wherein casting the vehicle support structure includes forming a cross member extending between the first and second opposing inner longitudinal beams.

7. The method of claim 5 , wherein (i) casting the vehicle support structure includes forming first and second opposing outer gunmetal longitudinal rails that partially form the front body structure, (ii) the first outer gunmetal longitudinal rail is disposed laterally outward from the first inner longitudinal rail relative to the engine compartment, and (iii) the second outer gunmetal longitudinal rail is disposed laterally outward from the second inner longitudinal rail relative to the engine compartment.

8. The method of claim 6 , wherein (i) casting the automotive support structure includes defining first and second openings configured to receive a strut tower along the front vehicle body structure, (ii) the first opening is disposed between the first outer gun-type structural rail and the first inner rail, and (iii) the second opening is disposed between the second outer gun-type structural rail and the second inner rail.

9. The method of claim 1 , wherein (i) casting the automotive support structure includes forming first and second opposing rear side members that partially form the rear underbody structure, and (ii) the first and second opposing rear side members partially define first and second wheel wells.

10. The method of claim 9, wherein casting the vehicle support structure includes forming at least one cross member extending between the first and second opposing rear side members.

11. A method of manufacturing a vehicle body, comprising: casting an automotive support structure, the automotive support structure defining a front body structure and a rear underbody structure; physically disassembling the vehicle support structure to remove the front body structure from the rear underbody structure; securing the front body structure to the rocker panel along a front end thereof after the splitting; and The rear underbody structure is fixed to the rocker panel along a rear end thereof after the splitting, so that the front body structure is spaced apart from the rear underbody structure via the rocker panel.

12. The method of claim 11, wherein (i) casting the automotive support structure includes forming first and second opposing inner longitudinal beams that partially form the front body structure, and (ii) the first and second opposing inner longitudinal beams define an engine compartment therebetween.

13. The method of claim 12 , wherein (i) casting the vehicle support structure includes forming first and second opposing outer gunmetal longitudinal rails that partially form the front body structure, (ii) the first outer gunmetal longitudinal rail is disposed laterally outward from the first inner longitudinal rail relative to the engine compartment, and (iii) the second outer gunmetal longitudinal rail is disposed laterally outward from the second inner longitudinal rail relative to the engine compartment.

14. The method of claim 11, wherein (i) casting the automotive support structure includes forming first and second opposing rear side members that partially form the rear underbody structure.

15. A method of manufacturing a vehicle body, comprising: casting the front body structure and the rear underbody structure into a first integrated structure; cutting the first integrated structure to separate the front body structure from the rear underbody structure; securing the front vehicle body structure to a first region of a pair of opposing rocker side rails; and The rear underbody structure is secured to a second region of the pair of opposing rocker side rails such that the front body structure, the rear underbody structure, and the pair of opposing rocker side rails form a second integrated structure, wherein the front body structure and the rear underbody structure are spaced apart from each other within the second integrated structure.

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