Faculty of Engineering

Advanced Lightweight Construction

Introduction
Topology optimization
Form lightweight design of a wheel rim star
• Aim: changing and adapting a structure, by creating an
optimal force distribution and shape, respecting the given
requirements, for getting a structure with minimal mass.

• The main statement of this strategy is: “use only

material, where it will be needed.”

• Form lightweight design focus next to the mass reduction

also on loads, design space, manufacturing technology,
functional integration and load applications

• A very closed link between form, material and concept

lightweight design.

© Technische Hochschule Rosenheim, 18 March 2024, Page 16 Source: Henning, F. und Moeller, E.; Klein, B.; Ruff, M.
 Faculty of Engineering
Advanced Lightweight Construction

Introduction
Manufacturing lightweight design
Aim: mass reduction based manufacturing, production and assembly processes.

• not possible to make an isolated consideration of this strategy

• allows new possibilities and ways to design a part or to use a material, which cannot be
applied by classical or other manufacturing technologies

• Joining processes like welding or bonding can be also seen as a manufacturing lightweight
strategy, more homogeneous connections can be realized

© Technische Hochschule Rosenheim, 18 March 2024, Page 17 Source: Henning, F. und Moeller, E.; Klein, B.; Ruff, M.
 Faculty of Engineering
Advanced Lightweight Construction

Introduction
Lightweight Strategies in Product development process
Product / Task

Main system Part

Problems and Potentials Problems and Potentials

Concept lightweight design Number and type of functions

Constraint lightweight design Choice of suitable construction

Manufacturing and form lightweight design Material lightweight design

Form lightweight design

Mass
ok?
Manufacturing lightweight design

Theoretical Product

Construction and Engineering

Function,
Lessons learnt costs,
mass ok?
Aim

© Technische Hochschule Rosenheim, 18 March 2024, Page 18 Source: Friedrich