Development of a Lightweight Car Body, Using Sandwich-design

At the Institute of Vehicle Concepts of the German Aerospace Center (DLR), a light vehicle concept is developed, with a body in white structure of only 90 kg and a high level of damage tolerance, in case of accidents. The structural concept is a consequent implementation of hybrid materials, resulting in a lightweight structure made of few parts with relatively simple shape. This is achieved by adapting materials and using a sandwich architecture for structural components. Especially structural foams and honey comb for cores in combination with metallic sheets are qualified. Hereby a high lightweight design potential is achieved and an overall concept of a weight optimized, multifunctional and highly integrated body in white structure is generated and analysed by using finite element method (FEM)- crash simulation. As a feasibility study of the design, a full size body in white demonstrator was built. Also, tests of several components are performed, in order to validate the simulation results. Future developments will result in the assembly of a roadworthy prototype with a fuel-cell drive-train, as well as crash testing of the entire body in white.


  • English

Media Info

  • Media Type: Digital/other
  • Features: Figures; Photos; References; Tables;
  • Pagination: 11p
  • Monograph Title: Transport Research Arena (TRA) 2014 Proceedings

Subject/Index Terms

Filing Info

  • Accession Number: 01529770
  • Record Type: Publication
  • Files: VTI, TRIS, ATRI
  • Created Date: Jun 30 2014 9:44AM