Conceptual Development of Hybrid
Structures Towards Eco-Efficient
Vehicle Lightweighting
Alexander Kaluza, Tim Fröhlich, Sebastian Kleemann,
Wolfgang Walk, Christoph Herrmann, Stephan Krinke
and Thomas Vietor
Abstract Lightweight design is a major strategy in automotive development. The
dominant motivation is a reduction of use-phase energy demands while retaining or
improving technical performance. The application of new materials is the prevalent
lightweighting strategy. Modern vehicle concepts extend material substitution up to
the combination of different materials on a component level, so called hybrid
designs. While engineering processes, methods and tools in design and production
engineering are well established for conventional designs, hybrid designs pose new
challenges. Lightweight materials as well as new manufacturing and recycling
processes may cause increased environmental impacts. In order to achieve
eco-efficient lightweight structures, energy savings from the vehicles’ use phase
need to compensate additional burdens in other lifecycle stages. The current work
presents findings gained in a public-private research collaboration. Its starting point
is the understanding of the role of life cycle engineering towards its impact on
overall sustainability goals. Based on derived key requirements, an integrated life
cycle engineering approach is developed. Activities and interfaces between life
cycle engineering, component design and manufacturing are elaborated. A special
focus is set on the conceptual design stage, as emerging materials and manufacturing technologies lead to a broader concept variety. This stage presents also a
major lever for shaping the life cycle environmental impact of components.
A. Kaluza (&) Á T. Fröhlich Á S. Kleemann Á W. Walk Á C. Herrmann
S. Krinke Á T. Vietor
Open Hybrid LabFactory e.V., 38440 Wolfsburg, Germany
e-mail: a.kaluza@tu-braunschweig.de
A. Kaluza Á C. Herrmann
Chair of Sustainable Manufacturing and Life Cycle Engineering,
Institute of Machine Tools and Production Technology (IWF),
Technische Universität Braunschweig, 38106 Brunswick, Germany
T. Fröhlich Á S. Kleemann Á T. Vietor
Institut for Engineering Design, Technische Universität Braunschweig,
38106 Brunswick, Germany
W. Walk Á S. Krinke
Volkswagen AG, 38440 Wolfsburg, Germany
© The Author(s) 2018
E. Benetto et al. (eds.), Designing Sustainable Technologies,
Products and Policies, https://doi.org/10.1007/978-3-319-66981-6_21
181
Structures Towards Eco-Efficient
Vehicle Lightweighting
Alexander Kaluza, Tim Fröhlich, Sebastian Kleemann,
Wolfgang Walk, Christoph Herrmann, Stephan Krinke
and Thomas Vietor
Abstract Lightweight design is a major strategy in automotive development. The
dominant motivation is a reduction of use-phase energy demands while retaining or
improving technical performance. The application of new materials is the prevalent
lightweighting strategy. Modern vehicle concepts extend material substitution up to
the combination of different materials on a component level, so called hybrid
designs. While engineering processes, methods and tools in design and production
engineering are well established for conventional designs, hybrid designs pose new
challenges. Lightweight materials as well as new manufacturing and recycling
processes may cause increased environmental impacts. In order to achieve
eco-efficient lightweight structures, energy savings from the vehicles’ use phase
need to compensate additional burdens in other lifecycle stages. The current work
presents findings gained in a public-private research collaboration. Its starting point
is the understanding of the role of life cycle engineering towards its impact on
overall sustainability goals. Based on derived key requirements, an integrated life
cycle engineering approach is developed. Activities and interfaces between life
cycle engineering, component design and manufacturing are elaborated. A special
focus is set on the conceptual design stage, as emerging materials and manufacturing technologies lead to a broader concept variety. This stage presents also a
major lever for shaping the life cycle environmental impact of components.
A. Kaluza (&) Á T. Fröhlich Á S. Kleemann Á W. Walk Á C. Herrmann
S. Krinke Á T. Vietor
Open Hybrid LabFactory e.V., 38440 Wolfsburg, Germany
e-mail: a.kaluza@tu-braunschweig.de
A. Kaluza Á C. Herrmann
Chair of Sustainable Manufacturing and Life Cycle Engineering,
Institute of Machine Tools and Production Technology (IWF),
Technische Universität Braunschweig, 38106 Brunswick, Germany
T. Fröhlich Á S. Kleemann Á T. Vietor
Institut for Engineering Design, Technische Universität Braunschweig,
38106 Brunswick, Germany
W. Walk Á S. Krinke
Volkswagen AG, 38440 Wolfsburg, Germany
© The Author(s) 2018
E. Benetto et al. (eds.), Designing Sustainable Technologies,
Products and Policies, https://doi.org/10.1007/978-3-319-66981-6_21
181