Zukunftstechnologien für den multifunktionalen Leichtbau – serie

This book comprises the proceedings of the conference “Future Automotive Production 2022”, which took place in Wolfsburg. The conference focused on hybrid lightweight design, which is characterized by the combination of different materials with the aim of improving properties and reducing weight. In particular, production technologies for hybrid lightweight design were discussed, new evaluation methods for the ecological assessment of hybrid components were presented and future-oriented approaches motivated by nature for the development of components, assemblies and systems were introduced.Lightweight design is a key technology for the development of sustainable and resource-efficient mobility concepts. Vehicle manufacturers operate in an area of conflict between customer requirements, competition and legislation. Material hybrid structures, which combine the advantages of different materials, have a high potential for reducing weight, while simultaneously expanding component functionality. The future, efficient use of function-integrated hybrid structures in vehicle design requires innovations and constant developments in vehicle and production technology. There is a great demand, especially with regard to new methods and technologies, for "affordable" lightweight construction in large-scale production, taking into account the increasing requirements with regard to variant diversity, safety and quality.

This book comprises the proceedings of the conference “Future Automotive Production 2022”, which took place in Wolfsburg. The conference focused on hybrid lightweight design, which is characterized by the combination of different materials with the aim of improving properties and reducing weight. In particular, production technologies for hybrid lightweight design were discussed, new evaluation methods for the ecological assessment of hybrid components were presented and future-oriented approaches motivated by nature for the development of components, assemblies and systems were introduced.Lightweight design is a key technology for the development of sustainable and resource-efficient mobility concepts. Vehicle manufacturers operate in an area of conflict between customer requirements, competition and legislation. Material hybrid structures, which combine the advantages of different materials, have a high potential for reducing weight, while simultaneously expanding component functionality. The future, efficient use of function-integrated hybrid structures in vehicle design requires innovations and constant developments in vehicle and production technology. There is a great demand, especially with regard to new methods and technologies, for "affordable" lightweight construction in large-scale production, taking into account the increasing requirements with regard to variant diversity, safety and quality.

This book comprises the proceedings of the conference “Circularity Days 2024”, which took place from May 15th-16th in Wolfsburg.The conference focused on key topics such as Design for Remanufacturing, Circular Production, and Sustainable Materials and Applications. The emphasis was placed on products that are easily disassembled, repaired, and remanufactured, utilizing innovative manufacturing methods to minimize resource consumption, energy usage, and emissions, and highlighting eco-friendly materials and their role in achieving circularity. Especially circular production methods, which combine the advantages of minimal resource consumption and maximal reusability, have a high potential for reducing the environmental impact, while simultaneously extending the product lifecycle. The future, efficient and scalable integration of sustainable materials and circular production methods requires innovations and constant developments in design and manufacturing technology. This is an open access book.

This book comprises the proceedings of the conference “Circularity Days 2024”, which took place from May 15th-16th in Wolfsburg.The conference focused on key topics such as Design for Remanufacturing, Circular Production, and Sustainable Materials and Applications. The emphasis was placed on products that are easily disassembled, repaired, and remanufactured, utilizing innovative manufacturing methods to minimize resource consumption, energy usage, and emissions, and highlighting eco-friendly materials and their role in achieving circularity. Especially circular production methods, which combine the advantages of minimal resource consumption and maximal reusability, have a high potential for reducing the environmental impact, while simultaneously extending the product lifecycle. The future, efficient and scalable integration of sustainable materials and circular production methods requires innovations and constant developments in design and manufacturing technology. This is an open access book.

This book comprises the proceedings of the conference “Faszination Hybrider Leichtbau 2018”, which took place in Wolfsburg.The conference focused on new methods and technologies for the development and production of multifunctional and hybrid lightweight solutions in large-scale vehicle manufacturing. Further, it promoted the exchange of insights and lessons learned between experts from industry and academia.Lightweight design and construction are key technologies for the development of sustainable and resource-efficient mobility concepts. Material hybrid structures, which combine the advantages of different materials (e.g. fiber-reinforced plastics and metals), have a high potential for reducing weight, while simultaneously expanding component functionality. However, the efficient use of functional integrated hybrid structures in vehicle construction, requires innovations and constant developments in vehicle and production technology. There is a great demand for affordable lightweight construction in mass production that takes into account the increasing requirements in terms of variant diversity, safety and quality- particularly with regards to new methods and technologies.

Dieses Buch stellt den Abschlussbericht zum Verbundprojekt ProVorPlus vor. ProVorPlus leistet Beiträge zur anwendungsnahen Erforschung und Entwicklung großserientauglicher Fertigungs- und Produktionstechnologien für die wirtschaftliche Herstellung hybrider Leichtbaukomponenten und zum Aufbau von Prozessen zur Erzeugung flächiger Multi-Material-Fahrzeugstrukturen. Darüber hinaus werden Erkenntnisse über neuartige Produktionstechnologien vorgestellt, die zum einen die automatisierte Fertigung komplexer Vorformlinge in Multi-Material-Bauweise und zum anderen die Endkonsolidierung hybrider Bauteile durch die Verkettung von Einzelprozessen ermöglichen. Es wird dargestellt, wie die Technologien zum Abschluss in einer Prozesskette abgebildet und in Form von Anlagentechnik in der Open Hybrid LabFactory umgesetzt wurde.

Das Buch stellt den Abschlussbericht zumVerbundprojekt KonText vor. Das wesentliche Anliegen des Verbundprojektes war die Reduzierung der Kosten von FVK-Bauteilen durch die Bereitstellung eines textilen Fertigungsprozesses und die nachfolgende Herstellung kraftflussgerechter thermoplastischer Faserverbundbauteile. Hierzu wurde die gesamte Prozesskette von der C-Faser-Optimierung, über die Fertigungs- und Struktursimulation von kraftflussgerechten Textilien sowie Anlagenentwicklung und -erprobung bis zur Herstellung der Bauteile mittels klassischer Großserientechnik „Umformen“ bereitgestellt. Das Verbundprojekt wurde im Rahmen der ForschungsCampus Initiative „Open Hybrid LabFactory“ durchgeführt.

Das Buch stellt den Abschlussbericht des Verbundprojektes „TroPHy2“ vor. In dem Projekt wurde eine Hybridrollformanlage entwickelt, mit der Hybridbauteile aus Metallprofilen und Kohlenstofffasern mit thermoplastischer Matrix hergestellt werden können. Diese Anlage wurde im Technikum der Open Hybrid LabFactory in Wolfsburg aufgebaut. Die Partner untersuchten und validierten die notwendigen Fertigungsprozesse. Ziel war es ein strukturmechanisch optimiertes, hybrides Automobilbauteil zu entwickeln, welches die Gewichtseinsparpotenziale hybrider Werkstoffe darstellt. Es wurde eine Gewichtsersparnis von bis zu 44,9 % errechnet, womit das zu Projektbeginn gesetzte Ziel von 25 % Gewichtsersparnis signifikant übertroffen wurde. Die Leichtbaupotenziale des hybriden Werkstoffes wurden dadurch deutlich herausgestellt.

This book comprises the proceedings of the conference “Future Production of Hybrid Structures 2020”, which took place in Wolfsburg.The conference focused on hybrid lightweight design, which is characterized by the combination of different materials with the aim of improving properties and reducing weight. In particular, production technologies for hybrid lightweight design were discussed, new evaluation methods for the ecological assessment of hybrid components were presented and future-oriented approaches motivated by nature for the development of components, assemblies and systems were introduced.Lightweight design is a key technology for the development of sustainable and resource-efficient mobility concepts. Vehicle manufacturers operate in an area of conflict between customer requirements, competition and legislation. Material hybrid structures, which combine the advantages of different materials, have a high potential for reducing weight, while simultaneously expanding component functionality. The future, efficient use of function-integrated hybrid structures in vehicle design requires innovations and constant developments in vehicle and production technology. There is a great demand, especially with regard to new methods and technologies, for "affordable" lightweight construction in large-scale production, taking into account the increasing requirements with regard to variant diversity, safety and quality.

This book comprises the proceedings of the conference “Future Production of Hybrid Structures 2020”, which took place in Wolfsburg.The conference focused on hybrid lightweight design, which is characterized by the combination of different materials with the aim of improving properties and reducing weight. In particular, production technologies for hybrid lightweight design were discussed, new evaluation methods for the ecological assessment of hybrid components were presented and future-oriented approaches motivated by nature for the development of components, assemblies and systems were introduced.Lightweight design is a key technology for the development of sustainable and resource-efficient mobility concepts. Vehicle manufacturers operate in an area of conflict between customer requirements, competition and legislation. Material hybrid structures, which combine the advantages of different materials, have a high potential for reducing weight, while simultaneously expanding component functionality. The future, efficient use of function-integrated hybrid structures in vehicle design requires innovations and constant developments in vehicle and production technology. There is a great demand, especially with regard to new methods and technologies, for "affordable" lightweight construction in large-scale production, taking into account the increasing requirements with regard to variant diversity, safety and quality.

This book presents the final report of the collaborative research project "MultiMaK2": MultiMaK2 contributed to the development of multi-material component concepts in large-scale automotive production. Whithin the project new methods in conceptual design of lightweight components were developed at the example of roof cross member and transmission tunnels. A concurrent Life Cycle Design & Engineering approach led to identifying eco- and cost efficient component alternatives. This includes evaluation tools for the concepts' full life cycle. Further, methods to integrate that knowledge into automotive engineering processes have been established based on principles of visual analytics. That brings forward a tight integration of data, engineering models and results visualization towards an informed knowledge building across disciplines. MultiMaK2 also compiled and structured design guidelines within a knowledge management system. All methods and tools have been embedded within the Life Cycle Design & Engineering Lab in the Open Hybrid LabFactory.