Development of a methodology for resource-efficient lightweight optimization through the analysis of mass reduction and mass redistribution potential in early stages of product development

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The challenges of lightweight design are not only the development of new materials and production technologies but above all the consideration of lightweight design potential in the early phases of product development. This early consideration allows the product developer to control the resources towards a lightweight solution. However, this resource-efficient lightweight design development only works purposefully if product and company-specific criteria are used for the potential analysis. In addition, by considering potentials for mass redistribution, it is possible to uncover even more lightweight potentials and achieve lightweight design goals that are only achieved inefficiently or even not achieved by a mere mass reduction. Current methods only insufficiently support the product developer in facing these challenges.The purpose of the present application is, on the one hand, to gain a deeper understanding of the most diverse motivations and criteria for lightweight design, and, on the other hand, to understand the reciprocal effects of mass reduction and mass redistribution goals. As a result, based on the findings, two methods will be developed that support the product developer in the multi-criteria mass reduction and mass redistribution. Both methods should be combined into one methodology, taking into account the basic research. This will finally be validated in several case studies in cooperation with industrial partners.