1. Interdisciplinary engineering processes: Concurrent engineering approaches
are an established concept in the development of vehicle structures. When it comes
to the design of hybrid or multi-material concepts, one has to face some specific
challenges. Lightweight structures based on hybrid or multi-material approaches
require new designs compared to established materials, comprehensive experience
is currently missing. Manufacturing technologies for hybrid designs are developing
rapidly with implications for parts’ design and life cycle evaluation. A particularly
high number of variations and gaps in LCA databases, e.g. manufacturing processes, disqualify click-and-rush LCA studies composed of standard modules. All
of the considered engineering disciplines have to deal with high uncertainties and
engineering processes that are even more dynamic than in conventional vehicle
development. Especially product development and manufacturing technology
development are to a certain extent parallel activities in the given case.
2 & 3. Cross-domain understanding and interoperability of domain-specific IT
tools: All domain-specific engineering activities require the assistance of advanced
methods and tools, e.g. numerical simulation regarding crash behaviour or manufacturing process simulations. In addition, the modelling of energy and resource
demands relies on complex models incorporating different data sources—from
static life cycle inventories to the simulation of different use patterns or the consideration of live manufacturing data. Typically, simplified key performance indicators and visualization techniques are used to exchange information between
disciplines. Their benefit lies in the easy interpretability. At the same time, the
understanding for cross-disciplinary interlinkages decreases. As the decision scope
shifts from the gate-to-gate perspective towards the whole product life cycle as well
as across life cycles, domain-specific methods and tools should allow an information flow across disciplines.
4. Accelerated transfer of research findings to industrial decisions: In the
context of lightweight structures, but similarly concerning technologies, innovation
cycles become shorter including a dynamic innovation network. Thus, academic
and industrial research to a certain extent parallel the development itself. Higher
dynamics in the interaction of stakeholders are the result.
5. Robust screening methods & tools for the acceleration of engineering processes: The introduction hybrid or multi-material lightweight structures significantly increases the solution space during the development of vehicle components.
This leads to suspension of traditional geometries, component boundaries or
installation spaces creating new challenges for methods and tools in the design
domain. Cost assessment faces new challenges due to the fast changing designs and
the evaluation of new materials, processes and geometries. For both environmental
assessment and cost assessment, one major challenge is the scaling up of the
applied models in order to predict the behaviour in vehicle mass production. This
increased complexity in all disciplines, from engineering design over manufacturing planning up to LCE, needs to be reflected in developing evaluation tools that
build on the described complexity, but enable to derive reliable decisions.
Conceptual Development of Hybrid …
187
are an established concept in the development of vehicle structures. When it comes
to the design of hybrid or multi-material concepts, one has to face some specific
challenges. Lightweight structures based on hybrid or multi-material approaches
require new designs compared to established materials, comprehensive experience
is currently missing. Manufacturing technologies for hybrid designs are developing
rapidly with implications for parts’ design and life cycle evaluation. A particularly
high number of variations and gaps in LCA databases, e.g. manufacturing processes, disqualify click-and-rush LCA studies composed of standard modules. All
of the considered engineering disciplines have to deal with high uncertainties and
engineering processes that are even more dynamic than in conventional vehicle
development. Especially product development and manufacturing technology
development are to a certain extent parallel activities in the given case.
2 & 3. Cross-domain understanding and interoperability of domain-specific IT
tools: All domain-specific engineering activities require the assistance of advanced
methods and tools, e.g. numerical simulation regarding crash behaviour or manufacturing process simulations. In addition, the modelling of energy and resource
demands relies on complex models incorporating different data sources—from
static life cycle inventories to the simulation of different use patterns or the consideration of live manufacturing data. Typically, simplified key performance indicators and visualization techniques are used to exchange information between
disciplines. Their benefit lies in the easy interpretability. At the same time, the
understanding for cross-disciplinary interlinkages decreases. As the decision scope
shifts from the gate-to-gate perspective towards the whole product life cycle as well
as across life cycles, domain-specific methods and tools should allow an information flow across disciplines.
4. Accelerated transfer of research findings to industrial decisions: In the
context of lightweight structures, but similarly concerning technologies, innovation
cycles become shorter including a dynamic innovation network. Thus, academic
and industrial research to a certain extent parallel the development itself. Higher
dynamics in the interaction of stakeholders are the result.
5. Robust screening methods & tools for the acceleration of engineering processes: The introduction hybrid or multi-material lightweight structures significantly increases the solution space during the development of vehicle components.
This leads to suspension of traditional geometries, component boundaries or
installation spaces creating new challenges for methods and tools in the design
domain. Cost assessment faces new challenges due to the fast changing designs and
the evaluation of new materials, processes and geometries. For both environmental
assessment and cost assessment, one major challenge is the scaling up of the
applied models in order to predict the behaviour in vehicle mass production. This
increased complexity in all disciplines, from engineering design over manufacturing planning up to LCE, needs to be reflected in developing evaluation tools that
build on the described complexity, but enable to derive reliable decisions.
Conceptual Development of Hybrid …
187