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INCREASING FUEL EFFICIENCY

Automotive Lightweighting

Government regulations (CAFE) and consumer demand for vehicles with increased fuel economy are accelerating. With different options available to achieve fuel economy targets, automotive lightweighting is emerging as a clear favorite.

Simulation for automotive lightweighting

While physical prototyping and testing can be costly and time consuming, returning limited results, simulation allows you to fully explore different lightweighting opportunities within automotive designs.  Learn more in this e-book.

Automotive lightweighting simulation in action

Explore specific lightweighting examples by clicking the nodes on the vehicle and view the associated simulation results.

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Hood

OBJECTIVE

Predict / Validate

PROCESS

Using data from a draping simulation, as-manufactured material properties were extracted and analyzed. Fiber orientations were determined and the structural integrity of the part was verified to determine that it met the functional specifications.

BENEFITS

  • Weight reduction
  • Strengthen

TYPE

100% carbon fiber

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Front fascia

OBJECTIVE

Optimize

PROCESS

Using flexible cloud solving, hundreds of different materials and design iteration scenarios were tested, to obtain the combination which yielded the lowest piece-part-cost and weight without taxing local computing resources.

BENEFITS

  • Weight reduction
  • Durability
  • Manufacturability

TYPE

100% plastic polymer

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Seat pans (2)

OBJECTIVE

Validate

PROCESS

The manufacturing process was simulated and a warpage analysis was performed to ensure the quality of the final part and validate the overmolding process before any tooling investments were made.

BENEFITS

  • Weight reduction
  • Meet safety requirements

TYPE

Overmolded composite blank

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Oil pan

OBJECTIVE

Predict

PROCESS

Fiber orientations were simulated and manipulated to optimize the strength of the part. The as-manufactured material properties were extracted to complete structural, thermal, and vibration analysis to ensure product performance.

BENEFITS

  • Weight reduction
  • Durability
  • Metal replacement

TYPE

Fiber-reinforced plastic

DATA ATTRIBUTES INFORMATION ARE HERE!! - NEEDS TO BE UPDATE FOR EACH CAR PARTS

Valve Cover w/ Integrated
Oil Separator

OBJECTIVE

Predict

PROCESS

Simulation was used during the design stage to make decisions based on the manufacturability, material, and thermal analysis, resulting in multiple components being combined into a single, integrated plastic part.

BENEFITS

  • Reduced part catalog
  • Reduced assembly & tooling costs
  • Reduced complexity
  • High level of integration
  • Weight reduction

TYPE

Assembly to a single plastic part

Generative Design

With the introduction of generative design, automakers are radically rethinking what's possible with lightweighting.  Minimizing mass and material use while maintaining high-performance standards and engineering constraints, generative design is opening a new era of innovative design and engineering solutions.

seat-belt-brack-general-motors-generative

Advanced materials

As vehicle designs and functional requirements become more advanced, so do the materials.  New materials are being developed every day, with more than 100 different types and grades of plastic used in the average vehicle.  For added strength and stiffness, fibers are injected into plastic parts during the manufacturing process.

Composite materials offer significant reductions in mass without sacrificing function.  Advanced materials can be grouped into four categories.

  • Processes (overmolding, microcellular injection)
  • Plastic resins
  • Short and long fiber materials
  • Continuous fiber composites

Controlling the orientation of reinforcing fibers during the manufacturing process affects the strength and resistance properties of the part.  Capturing these "as-manufactured" material properties is critical to performing accurate analysis.

How does simulation help?

Advanced materials require simulation tools designed to address analysis requirements. These materials react differently than traditional materials, due to their construction.  Our products help you address simulation requirements for automotive lightweighting applications.

Image: six ways simulation helps engineers

Direct from the industry

Learn from executives at leading companies as they share insights about trends in automotive lightweighting, the benefits of using plastics and composite materials, and the role of simulation.

  • DUPONT

    Jeff Sternberg, Global Automotive Technology Director

  • TREXEL, INC

    Steve Braig, President & CEO

  • DOW AUTOMOTIVE SYSTEMS

    Allan James, Composites Marketing Manager

  • CELANESE

    Jeff Helms, Global Automotive Manager

  • COMAU

    Martin Kinsella, Director of Advanced Materials & Process Technologies

  • GENERAL MOTORS

    Kevin Quinn, Director of Additive Design and Manufacturing

Software for automotive lightweighing

Talk to us

Call us toll-free or complete this form to speak with us about our full portfolio of automotive lightweighting solutions.

Call 1-855-612-9998 (toll-free in US)

Lines open Monday through Friday, 9am to 5pm.

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Learn about additive manufacturing, subtractive CNC machining, injection mold simulation, hybrid manufacturing, factory planning, and all the capabilities of our complete portfolio of automotive manufacturing solutions.

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