Integration of the system lightweight design into the development process of new mobility systems

The development of lightweight products must also be controlled and supported across components. Therefore, new methods and processes for the design of complex systems are developed and existing approaches are adapted to apply them on the level of the overall system. Thus, lightweight design solutions at the interfaces to the application-specific technology-topics (Powertrain Systems, Chassis & Suspension and Vehicle Concepts) can be integrated into the overall development process of new generations of mobility systems at an early stage. 

Simulation, optimization and design methods that support the entire product development process of lightweight systems

In order to develop optimal lightweight design systems on every design level, methods relating to the whole product development process are explored. As early as in the concept phase, processual and structural optimization methods of the lightweight-oriented design of overall systems and multi-material designs are employed und extended purposefully. The particular stages of production, as well as the resulting behavior of the component are depicted virtually. Consistent CAE-chains serve the virtual coupling between design, manufacture and validation.

Development and research of lightweight material

The development of modern, customized composite material is based on the basic cross-scale knowledge about its chemical composition and its physical structure, from monomer to component. Especially the molecular structure, the interface development, and possible production-related defects determine the physical properties of a compound – conversely, the knowledge of these facts allow the customization of the material properties.

Sustainable production technologies and systems for multi-material lightweight structures

In the light of a sustainable production, the fabrication of lightweight structures requires innovative production technologies and systems. High volume production plants as well as agile production systems, that can adjust to volatile quantities and component variants flexibly and quickly, are needed. The focus lies on the production of fibre-reinforced plastic with duromers and thermoplastic matrices, as well as the integration of mechanic and electronic functional components in the multi-material design.

Circularity of lightweight design – sustainability and life cycle

Lightweight design offers great potential for the reduction of moving masses and the respective energy expenditure. To use the sustainability potential of lightweight construction material, especially composite material and hybrid material compounds, in the future, their circulation must be explored and optimized. The circularity includes a recycling-friendly design and a material-efficient production, as well as the possibility to reuse, repair or remanufacturing.

Validation and monitoring of lightweight design structures

A continuous monitoring of the total life cycle of the products and an early and process-accompanying validation is increasingly important for a sustainable and successful lightweight construction. At the Topic Lightweight Design we are researching experimental and virtual validation methods for a validated and consistent digitalization of the whole life cycle (digital twin). Digital twins and AI-based methods allow us to use the collected monitoring-data for quick and effective assessments of processes and components.