Over the past twenty years, through its DeltaWing Manufacturing Division, Green4U has established a reputation for innovation by developing a series of cumulative, disruptive technologies. While individual capabilities or technologies may have their own discrete impact on performance, their impact can be even greater when used in combination with other capabilities and technologies. For example, light-weighting capabilities such as the use of aluminum or carbon fiber in chassis and/or body design enables a vehicle, no matter if it is an ICE vehicle or an EV, to be more fuel-efficient. With an EV, however, a lighter vehicle makes it possible to add more batteries, which in turn increases the range of the vehicle. Likewise, a substantially smaller and lighter motor, such as the DHX motor, enables an EV manufacturer to add even more batteries, further increasing range. In this way, the use of several technologies in combination with others can have a cumulative impact that is greater than the sum of the impact of each technology when used separately.
A lighter vehicle will go further and faster on any given input of fuel than a vehicle that is heavier. Green4U has had experience with aluminum, as well as a variety of composites, including carbon fiber.

Aluminum Chassis: Green4U’s DeltaWing Manufacturing Division has used modular, extruded aluminum in chassis design since 1997. The aluminum structure makes the vehicle both lighter and stronger. A lighter body allows more batteries to be added extending the range of an electric vehicle. In terms of safety, Green4U vehicles have finished in the top 1.5% of crash tests, compared to vehicles using steel chassis.

Composites: Green4U’s DeltaWing Manufacturing Division has been using carbon fiber for car bodies and components for many years. All of the racing cars now being built have carbon fiber bodies. As a result of the extensive experience the Company has had working with composites, opportunities to make carbon fiber components for bus and aerospace manufacturers are now becoming available.
Developed by Dr. J. Rhett Mayor, formerly a professor at the Georgia Institute of Technology, the DHX motor is a high torque motor that uses a revolutionary cooling system that cools the motor at the motor’s heat source---the stator windings. As a result, the DHX Motor is 75% lighter and 75% smaller than a conventional motor with the same horsepower. Electric motors generate heat which is the enemy of a motor’s efficiency. The DHX motor uses an innovative liquid cooling system to reduce the heat that dissipates energy and torque. The DHX Falcon electric motor features standard materials, not exotic steels and magnets and achieves power densities of 120 horsepower per gallon (25kW per liter) and extraordinary torque of 195 ft-lbs/gallon (70 Nm/l).

The DHX motor has been developed by DHX Electric Machines, Inc. (“DHX”), which is located on the Green4U campus in Braselton. DHX has granted Green4U the exclusive worldwide rights for automotive applications for the DHX motor. Under a supply agreement, DHX will supply Green4U with an agreed number of motors at an agreed price.
Green4U’s engineers are working with a number of battery manufacturers, designers and experts from around the world to develop innovative ways to enhance battery technology used in its electric vehicles.

Battery Design: Green4U is developing a hybrid battery that combines the best properties of several different battery chemistries. The primary benefits of the hybrid battery are its regeneration capabilities, the safety of its design and its fast charging advantages.

B.I.C.E.P System: Separately, Green4U engineers have designed a system for connecting battery cells that is 50% lighter than existing battery connection systems.
As an offshoot of its work with composites, Green4U has developed REAMS, which stands for Recyclable Energy Absorbing Matrix, a multi-layer fabric that can be consolidated to form a rigid and impact-resistant protective layer in vehicles. In comparison to a Kevlar/Epoxy laminate, REAMS weighs approximately 42% less than the Kevlar material. The REAMS process is high-quality, strong, light weight, and cost-effective. REAMS also has interesting anti-ballistic qualities that, coupled with its low weight, may make it valuable for military and law enforcement applications.

REAMS uses existing material that is made in large quantities by a major U.S. company. Green4U originally experimented with using REAMS to make lightweight components before discovering its anti-ballistic capabilities. REAMS has been field-tested by Green4U, and is now undergoing testing by a third party test firm. REAMS can be fitted to the insides of a door panel or the floor board of a vehicle, and is light enough so that it does not require reinforced door hinges.
Green4U’s work in the electrification of vehicles began in 1998 when it designed and built the first hybrid race car, fifteen years ahead of the competition. In 1998, the Panoz Esperante GTR-1 Q9, nicknamed “Sparky,” was the first hybrid to be raced competitively at the 24 Hours of Le Mans, and was victorious at Petit Le Mans in that year. It was not until 2012 that Toyota and Audi next raced hybrids at Le Mans.
The innovative DeltaWing Vehicle Architecture reduces weight and drag and gives the DeltaWing coupe its signature fighter jet styling.
The DeltaWing coupe is approximately 50% of the weight of its competitors; requires 50% of the horsepower; and uses 50% of the fuel to go the same speed and distance a car built with conventional architecture.
During its 2012 launch, the DeltaWing earned:
  • “Best of What’s New In 2012,” Popular Science Magazine.
  • “Racing Car of the Year”, Automobile Magazine.
  • Pioneering and Innovation Award, Autosport Magazine.

  • When it was the Garage 56 entrant at 24 Hours of Le Mans in 2012, DeltaWing received 7.4 billion internet impressions, 28 million print impressions and 9.15 million television impressions, worth $90 million in advertising equivalence, exceeding the equivalent of a full year of racing in Formula One.