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Lightweight Design Strategies for Car Bodies


Designing and developing light weight vehicles ready for series production is becoming increasingly important. Especially for fully electric vehicles with large and heavy battery packs light car bodies are indispensable. But also for other propulsion concepts lightweight is desirable. This seminar will focus on production ready vehicle concepts. Ideas taken from the extreme light weight design are integrated into the considerations. A symbiosis of the use of modern lightweight materials and the design of appropriate lightweight structures leads to efficient lightweight design. This multi-disciplinary task is only possible with development strategies that can simultaneously handle requirements of crash protection, vehicle dynamics, comfort, acoustics, durability and production of the vehicle. The aim of this seminar is to provide the competencies for the development of light vehicle structures.

Who should attend?

This seminar is aimed at designers, analysis engineers and project managers from car body development.

Course Contents

  • Potentials of lightweight design
    • Motivation and problem definition
    • Current lightweight vehicle concepts
    • The "Lightweight Spiral"
  • Principles of lightweight design
    • Definition of requirements
    • Determination of design loads
    • Principal design rules
    • Approaches of bionics
    • Fail-safe, safe life, damage tolerance
    • Methodical concept finding (architecture, topology)
  • Materials and their specific design rules
    • Material selection
    • Acquisition of material data
    • Steel, aluminum, magnesium
    • Fiber composites
    • Material mix and recycling
  • Structures of lightweight design
    • Space-frame structures
    • Shell structures (beads, ribs, ...)
    • Foams and inlays
    • Composite sandwich structures
    • Related joining techniques (adhesive bonding, ...)
  • Advanced CAE methods for lightweight design
    • Stability (buckling, ...)
    • Dynamics and acoustics
    • Fracture mechanics, multi-scale models (observation of cracks, etc.)
    • Crash of small structures
    • Analysis of joints
    • Robustness analysis
    • Optimization of shape and dimension
  • Case studies
    • Selected Vehicle Components
    • Ultra-lightweight vehicle concepts
    • Vehicle concepts for mass production

Prof. Dr.-Ing. Axel Schumacher
University of Wuppertal

Schumacher Prof. Dr.-Ing. Axel Schumacher studied mechanical engineering at the universities of Duisburg and Aachen. He received his doctorate on structural optimization from the University of Siegen. Following research projects for Airbus were focused on the optimization of aircraft structures. Thereafter he worked in the CAE methods development department of Adam Opel AG as project leader for structural optimization. From 2003 - 2012 he was a professor at the University of Applied Sciences in Hamburg and taught structural design, passive safety and structural optimization. Since 2012 he has been professor at the University of Wuppertal, where he holds the chair for optimization of mechanical structures.

Date Language Price Code
01 Apr - 02 Apr 2020 Deutsch 1340 EUR  (1590 EUR from 05 Mar 2020 ) 3466
Alzenau ( gmbh, Siemensstraße 12, 63755 Alzenau) » Register
Prof. Dr.-Ing. Axel Schumacher (University of Wuppertal)
Seminar hours  
Wednesday 09:00 - 17:00
Thursday 09:00 - 17:00

This course is available as an in-house seminar. The trainer comes to your site - you save travel expenses and travel time. Get an offer.

Your contact person

Dr. Dirk Ulrich
Phone.: 06023 - 96 40 - 66

Request now!

All prices are exclusive of VAT.