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With the Elan's launch, Lotus is moving into a new era of low-volume production. By the middle of the next decade, a maximum of 3000 a year will be produced at Hethel and it was these requirements, combined with a desire for more design freedom, that led Lotus to carefully examine its current VARI (Vacuum Assisted Resin Injection) process and develop a unique, flexible system for the Elan. It was decided to develop a manufacturing process to employ a larger number of separate panels to allow future design freedom. The aim was to jig assemble panels which would allow accurate and consistent control of the complete assembly. Evaluation of alternative materials and processes for body panel manufacturing began in 1987, leading to the conclusion that the Lotus patented VARI process was still the most cost effective for the new car.