Development of a lightweight car body, using sandwich-design

Abstract

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 FEM- crashsimulation. 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.