Browse Topic: Lightweighting

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Topology Optimization of Lightweight for Frame Structure of Deep-Sea Mining Vehicle2026-99-01307/31/2026
In order to improve the self-sufficiency rate of key mineral resources in China, it is necessary to develop and research deep-sea mining vehicles to improve the mining capacity of seabed mineral resources. The deep-sea mining vehicle is a heavy-duty underwater robot, and its main frame structure, as a critical component, must be designed to be lightweight to improve payload capacity and mining efficiency. This paper first conducted static analysis for the initial main frame structure. Finite element analysis results indicate that the initial structure fails to meet the strength requirements for lifting and recovery operations. The power index penalty factor was introduced into the topology optimization, which was based on the variable density method. The topology optimization objective was set to minimize structural compliance, with the maximum element stress and volume fraction used as constraints. The optimization process finally obtained the optimal material distribution. According to the results of topology optimization and space requirements of the installed equipment on the deep-sea mining vehicle, the new frame structure of the mining vehicle was re-established in the secondary modelling. According to the results of the analysis, the weight of the frame structure was reduced by 2.9%, and at the same time, the maximum stress was reduced by 57.2%, the maximum displacement was reduced by 47.2%, and the first-order natural frequency was increased by 54%. The strength and stiffness of the frame structure were greatly improved.
Tao, Yichun, Yang, Mingyu
Design of Telescope Support Truss Based on Topology Optimization and Size Optimization2026-99-08487/30/2026
The primary mirror support truss of large-aperture segmented telescopes, serving as a critical load-bearing component of the optical system, has its structural stability directly determining the optical imaging quality. This paper adopts a collaborative design method integrating topology optimization and size optimization to address issues, including excessive weight and unreasonable stiffness distribution in traditional support truss designs. First, based on the topology optimization theory of the Solid Isotropic Material with Penalization variable density method, topology optimization was performed on the initial truss structure using finite element simulation software, with the volume fraction as a constraint and the objective of maximizing structural stiffness to determine the optimal material distribution model. Subsequently, the truss structure was reconfigured based on the topology optimization results. Finally, the cross-sectional dimensions of the truss members were selected as optimization variables, and size optimization was performed using the NSGA-II multi-objective optimization algorithm with the objectives of minimizing structural weight and minimizing weighted compliance, while considering constraints such as stress and displacement. The results show that the optimized support truss achieves a 3.9% reduction in weight and a 35.47% decrease in elastic strain energy. This effectively meets the high-precision and lightweight design requirements for telescope support structures and provides a feasible technical solution for the design of large-aperture telescope support trusses.
Tan, Deli, Guo, Liquan, Gao, Dedong, Liu, Chuanjie, Dai, Xiaodong, Huang, Lei
Design and Analysis of a Lightweight Offshore Gangway2026-99-08517/30/2026
During offshore wind power operation and maintenance activities, personnel transfer and boarding procedures involve numerous safety risks. is a highly effective solution for enhancing safety during ship transfers at sea. This paper designs a compact active motion-compensating lightweight gangway capable of compensating for multi-degree-of-freedom motions induced by sea waves, including roll, pitch, yaw, and heave. The structural design is first established, and based on this configuration, the output forces of the rotary electric cylinder, roll electric cylinder, and pitch electric cylinder are analyzed. A finite element method was employed to conduct a static analysis of the gangway under extreme loading conditions. Analysis of the first six modal orders revealed that the first natural frequency of the designed gangway is significantly higher than the wave frequency, thereby effectively preventing resonance phenomena. The forward transformation matrix of the gangway was simulated using the Denavit-Hartenberg (DH) method. Simulation results indicate that the working space of the lightweight gangway meets the preset motion range requirements, thereby validating the design’s feasibility. The designed compact passageway features simple operational control, high cost-effectiveness, minimal installation footprint, and low installation and control complexity, demonstrating high practicality.
Yu, Zhigang, Fu, Wanli, Zheng, Bowen, Wang, Zhuoqun, Fang, Jiwen
Characterization and Fatigue Life Validation of a Mass-Reduced Drum Brake Spider Made from a Modified and Nanostructured Cast Iron2026-36-03037/30/2026
This study aimed at the characterization and validation of a drum-brake spider with mass reduction, using a new concept of a nanostructured ductile cast iron alloy. There is a well-known effort in developing lighter, more competitive products with higher safety and longer service life for brake systems. One of the approaches that enables this type of development is the use of new materials capable of delivering superior performance. Conventional ductile cast iron alloys used in brake spiders exhibit limited mechanical properties, which restricts mass reduction while still ensuring high durability in service. One way to obtain high-performance ductile cast iron alloys is through heat treatments such as austempering (ADI), which provides significant gains in mechanical strength but involves high cost and environmental liabilities due to the use of salt baths. The modified and nanostructured ductile cast iron alloy proposed in this work exhibited mechanical properties in the as-cast condition that meet the standards for ADI-treated ductile irons, showing an increase of 102% in tensile strength and 78% in yield strength compared to the baseline spider. Based on this new material, a topology optimization was performed on the baseline spider model, resulting in an optimized design with a 40% mass reduction. The model was validated using casting simulation software, and tooling was manufactured for producing the new optimized spider samples in the nanostructured ductile cast iron alloy. Static mechanical properties and microstructure were determined and approved, allowing the fatigue testing phase to proceed. Initially, the spider samples were instrumented with electrical strain gauges and subjected to the standard structural bench test known as the Chuker test, which can simulate real operating conditions of the brake system. Considering that this test requires extended bench time, an accelerated durability test was developed for the new spider model using three servo-controlled hydraulic cylinders, based on the stress levels obtained. The results from the accelerated durability bench test demonstrated superior fatigue life for the optimized spider compared to the baseline model, also validating the new testing procedure.
Titton, Angelo Pradella, Tuzzin, Matheus, Lopes, Carlos H. R., Marcon, Lucas, Pereira, Leonardo, Tedesco, Jaime Luiz, Boaretto, Joel, Vieceli, Alexandre, Klein, Aloísio N.
Research on a Lightweight Door Based on an Approximate Model Constructed by a Differentiation Strategy2026-99-08127/30/2026
Taking the front door of a new energy vehicle as the research object, a finite element model was built based on HyperMesh to conduct stiffness and modal performance analysis, and clarify the characteristic differences of multiple responses of the door. To address the issue that traditional single approximation models are difficult to adapt to different response characteristics, a strategy for constructing differentiated approximation models is proposed, which is to select the optimal approximation model according to different response types. The results show that the approximation models for each response constructed based on the differentiation strategy have a fitting accuracy (R^2) of more than 0.99, close to complete fitting, which is significantly better than the overall adaptation effect of a single model. Finally, based on the approximate model established using this strategy, combined with a multi-objective optimization algorithm, the dimensions of the front door are optimized, while achieving lightweighting and performance improvement of the front door, which provides a new idea for constructing multi-response high-precision approximate models.
Wei, Yansai, Shen, Yongfeng
Analysis of the Hot Forming Behavior of AZ91 Magnesium Alloy2026-99-08387/30/2026
This study systematically discussed the high-temperature flow behavior of the Mg-Al-Zn based AZ91 alloy, which has significant application potential in modern aviation and automotive industries. The study was carried out in the temperature range of 250°C-450°C and the strain rate range of 0.001 s^−1 -0.1 s^−1, which met the typical industrial hot processing environment. The analysis of high-temperature flow behavior shows that the flow stress is inversely proportional to the deformation temperature and is proportional to the strain rate. An important finding is that the constitutive model parameters are significantly sensitive to strain, so the strain-compensated Arrhenius constitutive model is developed. The model shows high accuracy in predicting the thermal flow stress of AZ91, and provides a valuable calculation tool for the simulation and optimization of forming processes in aerospace parts manufacturing. The results show that the extruded original microstructure presents slender fine grains, while the deformed sample shows a temperature dependent transformation: the low-temperature bimodal structure evolves into uniform fine grains at intermediate temperature, and the grains begin to coarsen at high temperature. At constant high temperature, low strain rate promotes grain growth and twin formation, while high strain rate refines grains and inhibits twins, and dislocation slip is the dominant deformation mechanism. These findings provide vital guidance and support for optimizing hot working parameters of AZ91, and are particularly important for manufacturing lightweight components in aircraft structures and automotive systems. The established process performance relationship is helpful to develop energy-saving manufacturing strategies for transportation equipment, and supports the goal of reducing weight and improving performance in the industrial field.
Li, Jusen, Chang, Ming, Zhu, Wenyu, Sun, Haoran, Chen, Kaida, Yang, Xiaoyin, Zheng, Zhenhao, Zhao, Shengdun
Structure Design of the Composite Stabilizer for Civil Aircraft Based on Standards and Airworthiness Requirements2026-99-16037/24/2026
Generally, the allowable strain design is adopted for composite structures, which should ensure that the structure has sufficient strength and stiffness under the service load, and the safety margin should be greater than zero under the design load. The thesis develops a structured design for a stabilizer of civil aircraft based on standards and airworthiness requirements. The main task of this thesis is to compare the results of the all-mental structure and composite material structure of stabilizer on weight reduction at sufficient strength and stiffness.
Pi, Runge, Lv, Baoliang, Zhang, Liang
Dynamic and Static Optimization Design of Car-seat Structure2026-99-16147/24/2026
A car seat is one of the most critical components of passive safety. On the basis of the safety of car seats, this paper focuses on optimizing the design of the seat frame and achieving a lightweight design under various dynamic and static loading conditions. The optimization results are verified through physical experiments, which demonstrate the correctness and feasibility of the proposed design method. These experiments also provide research ideas for the optimization design of the seat structure and a certain reference value for the engineering application of the seat.
Shao, Youlin, Ni, Weiyu, Chen, Daojiong
Lightweight Optimization Design of Subframe Structure Based on Sensitivity Analysis2026-99-16397/24/2026
In order to meet the needs of national energy conservation and environmental protection policies, a typical chassis structure lightweight method based on sensitivity analysis of 13 strength conditions was proposed. Firstly, the finite element model of the subframe of a certain model is established, and the impact strength and static strength of the subframe structure are analyzed by the finite element method. Secondly, the sensitivity analysis of 13 strength conditions was carried out for the 12 main sheet thicknesses in the finite element model. Based on the results of the sensitivity analysis, the plate thickness of the components that is conducive to lightweight and has little impact on the 13 strength conditions of the subframe was selected as the design variable. The size optimization was carried out with the goal of minimizing the mass of the subframe and the constraint that the maximum Von Mises stress of the unit, where each material is located, did not exceed the yield strength of the material. The optimization results show that the performance of the subframe under 13 strength conditions meets the requirements of the index, and the weight of the subframe is reduced by 1.37 kg / 9.6%.
Jing, Min, Jia, Zhilong, Zhang, Hualei, Liu, Minjie, Gan, Xinhua, Gao, Jinyu
Analysis of Structural Stiffness Indicators of Manned Lunar Vehicles2026-99-18277/17/2026
The structural stiffness of a manned lunar vehicle is a core indicator ensuring its stable operation in the complex lunar environment. The vehicle’s body structure must meet multiple requirements, including high stiffness, lightweight design, and adaptability to lunar surface conditions. Since lunar gravity is only 1/6 of Earth’s and the terrain is rugged and dusty, the body structure must employ a high-stiffness design to withstand driving impacts and resist deformation, thereby preventing mechanical failures or safety hazards for crew members caused by excessive structural distortion. However, excessive structural stiffness would result in an overweight vehicle body, conflicting with the spacecraft’s lightweight requirements. Thus, the structural stiffness index should be optimized to a lower value while ensuring safe operation during lunar surface driving without compromising performance. This paper calculates and determines the structural bending and torsional stiffness indicators for the manned lunar vehicle’s body through simplified model calculation and the FEA method.
Shen, Zhenghui, Wu, Yingjia, Yang, Jianfeng, Wang, Weijun, Zhang, Chongfeng, Han, Liangliang
Multi-Objective Optimization Research and Design of Seat Structure in Vehicle Collision2026-99-05187/10/2026
The vehicles often accompanied by a huge impact in the collision process, high-quality and high-strength car-seats can better protect the safety of passengers. However, in the call for vehicle energy saving and emission reduction, the lightweight design of car-seats is imminent. Therefore, it is necessary to achieve lightweight seat weight while ensuring vehicle safety. Based on the dynamic condition of vehicle collision, this paper takes the rear seat of a certain model as the research object, takes multiple responses of the seat skeleton system as the target, establishes a multi-objective optimization model of the seat skeleton, determines the optimization result with the greatest comprehensive satisfaction, verifies the optimization result of the seat skeleton. The correctness and feasibility of the design method are proved.
Shao, Youlin, Ni, Weiyu, Chen, Daojiong, Cheng, Zhiqing
Study on Impact Resistance of Sandwich-Structured Battery Protection Panels2026-99-17285/22/2026
With new energy vehicles developing rapidly, battery safety, as an important part of the impact on the range of new energy vehicles and vehicle safety, has become the focus of attention. The battery pack protection plate is a core component to protect the battery, its performance needs not only impact resistance, but also lightweight, honeycomb sandwich structure with its excellent energy absorption characteristics and weight reduction performance by the battery pack protection plate performance research. At present, the core-to-face sheet interaction in conventional sandwich structures subjected to impact loads has not been fully elucidated, and the quantitative characterization of damage is insufficient, so this paper aims to optimize the lightweight impact-resistant structure by exploring the synergistic energy dissipation mechanism between the high-strength core material and the steel plate. The study combines theory and simulation, adopting ideal rigid-plastic film theory to establish a critical response model to predict the structural failure threshold, equivalent single-layer theory to simplify the analysis of plywood, and a stiffness matrix model to quantify the structural mechanical contribution of each layer. A two-material synergistic design framework is proposed by fully considering the material properties and adopting the corresponding intrinsic structure and failure criteria for different materials. Analysis reveals that geometric confinement is a key characteristic of the honeycomb sandwich panel’s response and a strain gradient driving mechanism at low impact resistance, and a new energy distribution paradigm is found through the analysis of the energy absorption ratio. The theoretical and simulation results are in great agreement with each other, which just has a difference of 0.7% in the peak force, 1.4% in the critical displacement error, and less than 2% in the impulse integration error. The proposed dual-material co-design framework provides a solution for electric vehicle battery protection systems that balances lightweight and impact resistance.
Zhang, Guanghao, Zhang, Mingming, Luo, Changjie, Zhou, Jun, Zhang, Fengqiang, Yu, Wenze, Li, Jiongfeng, Guo, Qingrong
Research on Fault Diagnosis Agent of Monorail Crane Based on Knowledge Graph and Lightweight Large Model2026-99-07415/15/2026
The monorail crane is important in mining operations, and its operation affects both safety and efficiency. Currently, fault diagnosis for monorail cranes has several challenges, such as heterogeneous mixing of multimodal data, poor use of knowledge, low real-time requirements, and high deployment costs for large-scale models. To solve these problems, we present an agent framework using a multimodal knowledge graph and a lightweight large model. In particular, we construct a fault knowledge graph for monorail cranes, organizing professional knowledge about components, failure modes, symptoms, and maintenance. By employing retrieval-augmented generation (RAG) technology, the knowledge graph is merged with the Qwen lightweight large model (low-rank adaptation) for fine-tuning to develop a diagnostic agent with task planning, tool invocation and memory. The experimental results show that the agent framework reduces “machine hallucination” and outperforms conventional diagnostic accuracy, response speed and resource efficiency, thus offering a safe and efficient solution for intelligent operation and maintenance of mining equipment.
Zhang, Yixuan, Xue, Shun, Bi, Xiang, Wei, Xing, Kang, Ranyu, Jue, Jie, Cheng, Liruiran
Supercritical Behavior Parameter Analysis of Single-piece Composite Drive Shaft for Tail Drive Line ApplicationF-0082-2026-00705/5/2026
The present study aims to investigate the dynamic behavior of composite drive shafts operating in the supercritical rotational speed regime, with a particular focus on the mode crossing and the potential emergence of vibratory instabilities. Composite shafts offer significant advantages in terms of mass reduction and mechanical properties, making them attractive for high-performance transmission systems such as helicopter drive lines. However, their operation beyond the first critical speed raises specific challenges related to stability, damping, and sensitivity to mechanical and operational parameters. To address these issues, an experimental and analytical framework was developed to explore a wide design space involving parameters that are known or suspected to influence supercritical behavior. These parameters include unbalance levels, support characteristics, flexible coupling properties, tightening conditions of the damper, and rotational speed. Particular attention was given to the analysis of the mode crossing phenomenon in composite supercritical shafts, as well as to the identification of the most influential contributors to the vibratory response within the defined experimental perimeter. Harmonic- and subharmonic-based analyses were conducted to assess the relevance of each parameter across different frequency regimes. Overall, the results indicate that, despite the wide parametric exploration, no dynamic instability was observed in the supercritical regime, thereby demonstrating the robust vibratory behavior of composite shafts and supporting their suitability for advanced helicopter transmission applications.
Barlet-Bas, Sébastien, Malburet, François, Lopez, Cédric, Pierrel, Bruno
Internal Structural Design Optimization for a Medium-Class Helicopter through the Load Path PredictionF-0082-2026-00765/5/2026
An internal layout design framework for a medium-class rotorcraft fuselage is attempted to build based on the idea of the energy-based load-transfer index. Load-transfer index will quantify the way in which the flight loads are distributed among the fuselage internal structural members. The static load-transfer analysis will identify an inefficient transfer region in the baseline fuselage configuration, and the resulting layout refinement will lead to a more unified load-transfer pattern and allow an additional weight reduction in the subsequent thickness-optimization stage. For a UH-60A aircraft, the existing literature provides well-established information for an airframe layout, finite-element modeling guideline, and ground vibration test correlation.
Chung, Eui-Cheol, Shin, SangJoon, Ahn, Chihyun, Kim, SungHyeon
Shape Optimization of a Single-Stator Dual-Rotor Axial Flux Motor for eVTOL AircraftF-0082-2026-02935/5/2026
Emerging technologies in the field of electrified propulsion systems offer a promising solution to reduce the dependence on fossil fuels and improve efficiency. However, the design of high-power density electric machines introduces new challenges, including limited passive cooling potential and the issue of the weight of electric motors. To address these challenges, this paper considers analysis and design methods for high torque-to-weight ratio axial flux motors. A magnetic equivalent circuit model coupled with a lumped parameter thermal network is developed for design space exploration and optimization. This inexpensive analytical model predicts the performance of a single-stator dual-rotor axial flux motor based on geometry, loading condition, and slot and pole pair combination. To enable comparisons against real-world data, the optimization study was demonstrated using the hover mission requirements from the Research Aircraft for eVTOL Enabling techNologies (RAVEN) vehicle to minimize the mass of the motor. In tandem with the analytical model, a higher-fidelity finite element model was also developed, and good agreement between predicted power and efficiency was demonstrated across a range of axial flux motor designs. The lightest weight design that satisfied the hover mission requirements was the 12 pole pair 27 slot (12PP 27S) configuration with a fixed weight of 9.28 kg. The analytic model undersized the output power of the electric motor by approximately 9% across a range of slot and pole pair combinations.
Arulampalam, Seiyon, German, Brian, Kennedy, Graeme, Smith, Cameron, Gutknecht, Jonathan
Lightweight Wheel Design Through Shape Optimization with Structural Constraints2026-01-05044/7/2026
The wheel rim is an annular, thin-walled structure featuring complex geometry and is subjected to multiple load cases, including radial, rotary, and impact scenarios. Achieving an optimal balance between mass reduction and structural performance remains a significant challenge in modern vehicle wheel design. Aero-efficient vehicles demand lightweight backbone wheels capable of accommodating aerodynamic covers without compromising handling, steering precision, or overall performance. In this study, shape optimization is applied to an 8-spoke truck wheel with the goal of minimizing mass while enhancing lateral stiffness and ensuring that stress constraints are satisfied under all critical load cases. A three-dimensional finite element model is developed and evaluated under realistic radial, rotary, and impact loading conditions representative of industry validation tests. The optimization process fine-tuned the spoke geometry using symmetric shape domains and carefully defined perturbation vectors, while preserving styling intent, bolt pattern, and brake packaging constraints. Lateral stiffness was evaluated using a frequency-based formulation derived from modal and frequency response analyses, while grid stress responses served as robust optimization constraints. The resulting optimized wheel achieved a mass reduction of approximately 5 percent, a lateral stiffness increase of approximately 30 percent, and a 6 percent rise in the first drum-mode frequency.
Yoo, Dong Yeon, Adduri, Phani, Chakravarty, Rajan
Multi-Physics Topology Optimization and Neural Network–Based Design of Experiments for Lightweight Automotive Cast Components2026-01-05104/7/2026
This paper presents a hybrid optimization framework that integrates Multi-Physics Topology Optimization (MPTO) with a Neural Network–surrogated Design of Experiments (NN-DOE) to enable lightweight structural design while satisfying crashworthiness, durability, and noise, vibration, and harshness (NVH) requirements under practical casting and packaging constraints. In the proposed MPTO formulation, crash and durability performances are incorporated through equivalent static compliance measures, while NVH performance is assessed using a frequency-domain dynamic stiffness metric, allowing consistent evaluation of trade-offs among competing design requirements. The framework is first demonstrated using a mass-produced passenger-car lower control arm (LCA) as a benchmark component. In this application, MPTO achieves weight reduction under multi-physics objectives by removing non-load-bearing material. Results show that single-discipline optimization produces unbalanced topologies, while balanced crash–durability–NVH consideration yields robust load paths. The study further demonstrates that crash and durability are dominated by static compliance–based response, whereas NVH performance is governed by frequency-dependent dynamic response over the relevant frequency range. The framework is then applied to a front engine mounting bracket of a newly developed heavy-duty truck. In this second application, a two-step strategy is employed in which MPTO first establishes the global load-carrying topology under manufacturing and packaging constraints, followed by NN-DOE–based local refinement to achieve stress attenuation at non-designable regions through global structural stiffness rebalancing, rather than direct geometric modification. Final verification confirms a steel-to-aluminum material transition achieving approximately 45% weight reduction and a substantial improvement in durability fatigue life, while maintaining required crash performance.
Kim, Hyosig, Senkowski, Andres, Gona, Kiran, Saroha, Lalit, Boraiah, Mahesh
Multi-Joint Topology Optimization Method with Interface Geometry Control2026-01-05034/7/2026
Topology optimization (TO) has become a reliable and lightweight design approach which was widely adopted in multiple industrial applications. Over the past decades, TO has advanced through three major development stages to increase its practicality and application scope: single-material topology optimization (SMTO), multi-material topology optimization (MMTO), and multi-joint topology optimization (MJTO). SMTO involves only one candidate material, whereas MMTO takes multiple candidate materials into consideration, which widen the application scope of TO. In terms of MJTO, it not only considers multiple candidate materials but also considers the bonding material between dissimilar candidate materials, improving practicality over MMTO. However, prior MJTO methods overlook the geometry of dissimilar material interfaces, a factor that may impact material bonding effect. In this paper, a novel MJTO algorithm is introduced to enable explicit control over interface geometry in MJTO. Central to the method is a Newton’s law of gravitation-inspired dissimilar material interface orientation detection approach, which accurately calculates the bonding material’s orientation. Using the orientation detection approach, the bonding material’s Young’s modulus can be penalized when undesired orientations occur, thus enforcing geometric control of the interface. In this paper, the proposed algorithm is evaluated through multiple academic models to demonstrate its effectiveness. Numerical study results demonstrate that the horizontal dissimilar material interface can be effectively controlled using the proposed method, leading to improved producibility of TO-derived designs.
Shi, Yifan, Huang, Yuhao, Kim, Il Yong
Lightweight Design of a Seat Module Assembly for a Robotic Arm Amusement Ride System Using Topology Optimization2026-01-04814/7/2026
This paper presents a methodology for the design of a lightweight seat module assembly (SMA) for an indoor robotic arm amusement ride. Typical SMA designs begin with a welded metal frame, and the exterior shell serves only as a non-structural cover, resulting in stress concentrations and excess weight. The proposed methodology introduces a bottom-up process that integrates topology optimization at the outset, enabling the outer shell to function as a primary load path and subsequently identifies the ideal configuration for internal secondary framing by utilizing manufacturing constraints. This approach is further enhanced by adopting fiber-reinforced polymers as the structural material, leveraging their high stiffness-to-weight ratio to replace conventional metallic designs. Multiple manufacturing-specific interpretations of the optimized design were explored to evaluate feasibility, including extrusion and tubing-based approaches. Finite element analysis of the final design under high intensity load cases verified that stress and displacement constraints were satisfied. This methodology achieved a 36% reduction in mass while increasing capacity from four to five seats, corresponding to a 49% reduction in mass per seat compared to the metallic baseline. The bottom-up process allowed for an integrated design approach, where the outer shell of the SMA was designed first, featuring a novel curved geometry which minimizes stress concentrations while contributing to the overall structural stiffness, followed by the integration of the internal structure. This methodology demonstrates a new direction for SMA design in the themed entertainment industry, where load path driven, composite-first approaches can reduce weight while increasing occupant capacity.
Pooler, Claire, Hronowsky, Benjamin, Chai, Kevin, Shi, Yifan, Park, Taeil, Lo, David, Kim, Il Yong
Application of Topology Optimization to Production-Ready Passenger Seat Components Design2026-01-04984/7/2026
Lightweighting of components has become a key challenge in the development of modern transportation systems. In the automotive and aerospace industries, the overall mass of a vehicle has a significant impact on its fuel efficiency and manufacturing cost. Therefore, the lightweight design of vehicle components is crucial in the industrial field. Topology optimization (TO) is a computational design approach aimed at achieving lightweight designs. However, most existing studies focus on simplified academic models, with limited demonstration in real-world applications. This paper presents a revised TO workflow to obtain production-ready design and a practical implementation of TO in the design of three structural components in the aerospace industry: seatback frame, seat fuselage mount, and seat spreader. The revised TO workflow incorporates the practical demands of industry, including enhanced manufacturability and cost efficiency through TO design. The resulting designs are evaluated to ensure all regulatory requirements are satisfied. Comparative results show that the designs produced by the presented TO-based design method achieve a significant weight reduction of 50% for the seatback frame. For the seat fuselage mount and seat spreader, the proposed method produced designs with a weight comparable to the baseline while satisfying stricter crashworthiness requirements. These components also ensure manufacturability, efficient fabrication cost, and compatibility with family parts. These findings demonstrate that TO can deliver production-ready solutions without compromising structural performance. The study highlights the potential of integrating TO into a revised design workflow to support performance-driven development of complex, production-ready industrial components.
Lee, Hanbok Jake, Shi, Yifan, Gray, Savannah, Orr, Mathew, Park, Taeil, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Jalayer, Shayan, Burns, Nicholas, Hansen, Eric, Grant, Robert, Kok, Leo, Kim, Il Yong
Multi-Material Topology Optimization Using Difference-Based Equivalent Static Load Method2026-01-01734/7/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving approximation accuracy. However, existing DiESL implementations are restricted to single-material topology optimization (SMTO), where elements can be either solid or void. In contrast, multi-material topology optimization (MMTO) allows multiple material candidates per element, offering greater design freedom and the potential for better solutions. For crashworthiness applications, MMTO can leverage low-density materials (e.g., aluminum or magnesium) to form thick members that resist buckling, while using high-strength, high-density materials (e.g., steel) in critical stress regions to prevent yielding. By combining MMTO with DiESL, nonlinear crash performance can be further improved, offering a promising framework for lightweight and crashworthy structural design.
Huang, Yuhao, Kim, Il Yong
From Algorithm to Engineering Judgment: Navigating Topology Optimization’s Limits in Crash Applications2026-01-01894/7/2026
The non-linear nature of crash scenarios has led to many designs being developed through extensive trial and error based on the intuitions of the design engineer. As such, effectively utilizing topology optimization for crash applications offers opportunities to provide major improvements in cost, weight, and passenger safety. Topology optimization is known for creating stiff, lightweight structures, however its application to crash scenarios must be handled carefully. Compliance minimization, the most common optimization objective, can yield misleading designs that prioritize undesirable qualities when developing structures for crash applications. In this paper, the design process of a passenger seat assembly subject to sequentially applied enforced displacement, and crash deceleration loads is discussed. Due to the conflicting nature of compliance minimization and enforced displacement, the design was split into two types of regions; sacrificial, which are regions manually designed to absorb the majority of the enforced displacement and crash energy, and structural, regions designed with optimization tools to maximize stiffness and reduce mass. The recognition of these regions allowed for components that failed during the crash phase to be remedied via the removal, rather than addition, of material in key sacrificial locations through alleviating stresses experienced during the enforced displacement phase. Identifying and using these design guidelines was shown to greatly improve seat performance metrics, and yielded reduced design times as failure mechanisms were clearly defined and designed, mitigating the issue of cascading failures across an assembly as individual failure modes are addressed.
Orr, Mathew, Shi, Yifan, Lee, Jake, Gray, Savannah, Park, Taeil, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Burns, Nicholas, Jalayer, Shayan, Grant, Robert, Kok, Leo, Hansen, Eric, Kim, Il Yong
Development of Automotive Hood Using Multi-Material Double Injection Molding – An Overview2026-01-04764/7/2026
This paper presents the multidisciplinary development of a hybrid automotive hood manufactured using double-shot injection molding with overmolded brackets. Conventional steel and aluminum hoods, while structurally reliable, pose challenges in terms of weight reduction, pedestrian head protection, and manufacturing cost. Composite and thermoplastic alternatives supported by computational analysis and advanced molding processes provide opportunities to address these challenges. Finite element analysis (FEA) was employed to evaluate torsional and bending stiffness, locking load, and crashworthiness, while pedestrian headform simulations following ECE R127 and EEVC WG17 guidelines were conducted to assess compliance with safety regulations. Adhesion and bonding strength of overmolded polymer–polymer interfaces were studied to validate manufacturing feasibility. Results confirm that hybrid hoods fabricated using multi-material double-shot molding can achieve weight reductions of up to 30% compared with steel, maintain structural stiffness equivalent to aluminum, meet head injury criterion (HIC) thresholds, and reduce assembly complexity by consolidating brackets and reinforcements into a single integrated structure.
Ganesan, Karthikeyan, Seok, Sang Ho, Jo, Hyoung Han
Analyzing Effects of Cell to Chassis Technology on Sound Transmission Loss of Skateboard- Sharing Vehicles2026-01-50243/30/2026
Limited published research has critically examined the impact of Cell-to-Chassis (CTC) structures on the Noise, Vibration, and Harshness (NVH) performance of electric vehicles (EVs), with most studies focusing on conventional Cell-to-Pack (CTP) systems. A concern is that vehicles employing CTC architectures may exhibit compromised NVH performance due to the absence of a dedicated floor panel. To investigate the NVH performance implications of the CTC structure, this study adopts a comprehensive methodology encompassing: (1) theoretical Sound Transmission Loss (STL) analysis utilizing mass law and double-panel principles, (2) finite element (FE) modeling of STL, (3) in-vehicle Acoustic Transfer Function (ATF) testing, and (4) interior noise measurements conducted at a constant 60 km/h on a smooth asphalt road. Simulation results demonstrate that, compared to a conventional CTP floor system, the studied CTC structure achieves a 5–40 dB increase in STL across the 200–2000 Hz frequency range. This finding is consistent with theoretical calculations. Furthermore, experimental results from in-vehicle ATF and interior noise tests reveal no significant acoustic difference in the 400–1400 Hz frequency range, which is primarily associated with tire noise, between a configuration with complete floor insulation (including carpeting) and one with insulation (including carpeting) removed from the CTC area. This research validates an effective simulation method for floor system STL and demonstrates that the acoustic insulation performance of the CTC structure enables potential cost and weight reductions by minimizing the requirement for traditional carpeting and sound insulation pads. This approach also suggests a pathway to reducing Volatile Organic Compound (VOC) emissions from these ancillary materials.
Xu, Xueying, Wang, Xiaoming, Ma, Caijun, Li, Guofu
Preliminary Design and Analysis of a Dual Throat Fluidic Thrust Vectoring Nozzle for Supersonic Aerospace Application2026-28-01062/12/2026
The Dual Throat Nozzle (DTN) is a unique nozzle configuration that enables fluidic thrust vectoring (FTV), improving aircraft maneuverability while reducing the mechanical complexity of traditional vectoring systems. In this study, a two-dimensional DTN was developed based on a validated NASA Langley model, incorporating a newly designed plenum geometry guided by area expansion ratio principles. Numerical simulations were carried out in ANSYS Fluent using a density-based, steady-state solver with the SST k–ω turbulence model to capture key compressible flow features such as shock waves, flow separation, and jet deflection. Secondary injection rates were determined using choked-flow relations, and a 12-case parametric study was conducted to analyze the effects of Nozzle Pressure Ratio (NPR), injection rate, and injection angle on thrust deflection and efficiency. The simulation results at NPR = 4 with 3% injection showed strong agreement with NASA experimental data, validating the computational setup. It was observed that higher NPR values reduced jet deflection but improved overall thrust efficiency, with the best performance achieved at NPR = 2 and a 150° injection angle. The findings provide valuable insight into optimizing DTN design parameters for lightweight, efficient fluidic thrust vectoring systems suited to future supersonic applications.
Suresh, Vignesh, M, Akash, Senthilkumar, Nikil, Sundararaj, Senthilkumar, A, Garry Kiristen, Singh, Swaraj
Optimization of the Hood Ro-dip CED Process Through Strategic Support Rod Placement at Multiple Locations for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is new technology used by automotive manufacturers for higher quality corrosion protection in new generation automobiles. This process involves multiple 360-degree rotation of automotive body-in-white (BIW) which exert higher hydrostatic pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel hood panel while undergoing through this CED process. This study investigates the enhancement of hood structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional inaccuracies, overall weight reduction and crash worthiness of vehicle.
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Material-Optimization in Rib-Stiffened Polymer Structures: A Computational & Analytical Study2026-26-04981/16/2026
The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. The current literature focuses on single ribbed or homogeneous plate behavior. Understanding the behavior in parallel rib arrangement with inter connections – especially when the ribs are spaced close together is yet to be done. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel dual-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending performance. The study attempts to understand the behavior of Polypropylene plates specifically, their bending stiffness, load transfer enhancement of the cross-rib structure through mathematical and computational methods. The study also compares the mechanical performance of single ribbed structure to that of parallel and cross-ribbed plates. The cross ribbed plate structure will help in increasing the packaging space and weight reduction.
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology2026-26-02751/16/2026
As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring their potential to enhance vehicular safety and reduce environmental impact through lightweight, energy-efficient lighting integration. Electroluminescent coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional external lighting and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, the uniform illumination achieved without bulky fixtures contributes to aerodynamic efficiency, supporting fuel economy and reducing carbon emissions. use of this coating system, can optimize tooled up plastic part and sub-assemblies specially to those parts we use for indication, marking, highlight & lighting assisting during dark This paper identifies and evaluates specific use cases where EL coatings can deliver substantial benefits: for example, Exterior Lighting systems, Perimeter Lighting for Night Operations, Ingress/degrees illumination with Integrated Safety Features, Emergency and Breakdown Visibility & Trucking illumination accessories. Accentuate brand specific, Technology & design features over a truck
Harel, Samarth Dattatraya, Borse, Manoj, L, Kavya
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative performance evaluation against steel cascade, supporting the advancement of hydrogen infrastructure.
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, examined a novel configuration wherein aluminum High-pressure die cast (single HPDC part) is introduced which covers swan neck region as well as the base of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal that the dynamic equilibrium approach offers a rational and most efficient framework for material allocation, allowing for the optimization of crash performance metrics while simultaneously achieving weight reduction. Compared to conventional all-steel or all-aluminum designs, the hybrid structure demonstrate efficient, improved crashworthiness, with measurable mass savings. By grounding material decisions in mechanical principles rather than empirical iteration, this research presents a scalable methodology applicable to a wide-range of vehicle platforms. The outcomes offer a compelling case for the adoption of multi-material architectures as a pathway toward enhanced crash safety and reduced environmental impact.
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-02811/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-02951/16/2026
To meet light weighting and safety targets, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties (YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio (HER) in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays an important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light-weighting of automotive body parts.
Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Structural Design and Simulation of Composite Metal Hybrid Based Battery Enclosure for an Electric Vehicle2026-26-03001/16/2026
Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was performed to optimize the weight of battery pack. The structural integrity and crashworthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Modal analysis and load tests addressed, demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications. Manufacturing aspects are also discussed to ensure feasibility and integration.
Shah, Bijay Kumar, Singh, Pundan Kumar, G., Manikandan
Lightweight Design and Optimization of Multi-Terrain Multi-Functional Tracked Amphibious Vehicle2025-99-032412/17/2025
In view of the complex intertidal terrain challenges faced by offshore wind power maintenance, this paper optimizes the lightweight design of multi-terrain tracked vehicles. The structure was optimized by finite element analysis, and the maximum stress was 211.68 MPa ( lower than the safety limit of 230 MPa), and the maximum deformation was 5.25 mm, which ensured the stability and stiffness. Titanium alloy has the advantages of high strength, low density and corrosion resistance, which improves the durability of the frame while reducing the weight of the frame. Advanced manufacturing technologies such as phase transformation superplastic diffusion welding optimize the connection between TC4 titanium alloy and stainless steel. Modal analysis and optimization techniques refine the structural parameters and improve the complex load performance. The research promotes the lightweight of the frame and provides theoretical and technical support for the design of multi-terrain vehicles.
Xu, Han, Xu, Shilin, Ma, Wenbo, Zhu, Wei
Aerospace & Defense Technology: December 202525AERP1212/4/2025
High-Flying Output: Key Machining Techniques for Structural Aircraft Components Future-Proofing the Tactical Edge: Converging AI, Edge Processing, and Hybrid Cloud for Modern Battlefield Operations Digitally Transforming the Future of Defense: Collaborative Combat Aircraft How Lightweight Coatings Protect Aerospace and Defense Electronics How the US Space Force is Leveraging Commercial Antennas for Defense Applications German Researchers Test Quantum Channels In-Flight Researchers at the German Aerospace Center recently tested a quantum sensor in-flight on a Dornier 228 research aircraft. Novel Chromium-Molybdenum Metal Alloy Withstands Extreme Conditions A new high-temperature resistant material exhibits great potential for applications such as energy-efficient aircraft turbines. Electric Propulsion for a Nuclear-Powered Spacecraft Nuclear microreactors could improve the performance of electric propulsion systems in spacecraft. Controlling Heat Spikes in Electric Aircraft at Takeoff Researchers from Brazil are collaborating with a team at Embry-Riddle Aeronautical University to develop new methods for controlling heat spikes generated by electric aircraft during the takeoff phase of flight.
Altair lauds lightweight-engineering efforts25AUTP12_1812/1/2025
Winners of the 13th edition of the Altair Enlighten Awards, presented in association with the Center for Automotive Research, were recognized during a ceremony at the CAR Management Briefing Seminars in Detroit. The awards not only acknowledged the automotive industry's best initiatives to reduce vehicle weight and meet emissions targets, but also considered other parameters such as cost reduction, part count reduction and applicability to other vehicle programs. “Starting in the 2000s, the automotive industry wasn't really that interested in optimization. Weight was an outcome of achieving performance. Seeing the rise of these digital technologies over two decades has been such a thrill,” Royston Jones, CTO of Altair Product Design and senior VP for automotive, said to kick off the event. “I'd say now we're really through the gate, particularly over the last five years where globally there's such pressure to develop products quickly. AI has really helped with technology such as optimization, so I think it's only going to accelerate, it's going to get smarter. This is such an exciting time to be in this digital space.”
Gehm, Ryan
Altair lauds lightweight-engineering efforts25TOFHP12_0712/1/2025
Winners of the 13th edition of the Altair Enlighten Awards, presented in association with the Center for Automotive Research, were recognized during a ceremony at the CAR Management Briefing Seminars in Detroit. The awards not only acknowledged the automotive and commercial vehicle industries' best initiatives to reduce vehicle weight and meet emissions targets, but also considered other parameters such as cost reduction, part count reduction and applicability to other vehicle programs. “Starting in the 2000s, the automotive industry wasn't really that interested in optimization. Weight was an outcome of achieving performance. Seeing the rise of these digital technologies over two decades has been such a thrill,” Royston Jones, CTO of Altair Product Design and senior VP for automotive, said to kick off the event. “I'd say now we're really through the gate, particularly over the last five years where globally there's such pressure to develop products quickly. AI has really helped with technology such as optimization, so I think it's only going to accelerate, it's going to get smarter. This is such an exciting time to be in this digital space.”
Gehm, Ryan
Thermal Model of a Traction Inverter for an Automotive Application, Including DC-Link Capacitor, Power Modules and Electrical Connections2025-01-051911/25/2025
In automotive applications a power electronic converter is used for energy conversion between battery and electrical machine. For high performance drives a lightweight design is demanded. Additionally, a higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modeling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modeling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on physical properties and geometries. First, the DC-link capacitor thermal model is presented and considers the anisotropic heat conductivity of the capacitor coil and the inhomogeneous loss feeding in the busbars. Next, the thermal model of a power module and heatsink is explained taking temperature dependent material properties into account. Based on the input temperature of the coolant and heat dissipation of the power modules the temperature rise of the fluid is calculated. Furthermore, the electrical connections, consisting of a combination of cables, busbars and shunts are thermally modeled. With the individual component models combined an overall inverter thermal model is developed. A comparison between the thermal system model and measurements is carried out finally. For this several temperature sensors were integrated into an inverter. By taking the measured temperatures into account, the thermal system model is validated for stationary and dynamic load points. As all models are based on geometric and material properties it is possible to observe the impact of sizing in the future.
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-028111/6/2025
Electrification applications are increasingly moving towards higher voltage systems to enable greater power delivery and faster battery charging. This trend is particularly evident in the shift from 400V to 800V systems, which offers several benefits and poses unique technical challenges. Higher voltage systems reduce current flow, minimizing energy losses, and improving overall efficiency. This is crucial for applications like electric vehicles and off-highway machinery, where efficient power management is essential. One of the primary benefits of increasing the DC link voltage beyond the 400V is the ability to support higher power levels. Additionally, higher voltage systems can reduce the size and weight of power components, contributing to more compact and lightweight designs. However, transitioning to 800V systems introduces several technical challenges in power electronics design. Key components such as power components (IGBT, MOSFET etc.) must be optimized to handle higher voltages and currents, requiring advanced thermal management solutions to dissipate the increased heat generated. Insulation and isolation for PCB design become more critical at higher voltages, necessitating robust insulation materials and techniques to prevent electrical breakdowns and ensure safety. Gate drivers and digital isolators must handle high-frequency transients and maintain reliable operation in high-voltage environments. A comprehensive review of these critical components and their reliability aspects is essential for the successful implementation of 800V systems in electrification applications. Addressing these challenges through innovative design and advanced materials will pave the way for more efficient, reliable, and high-performance power electronics solutions.
Hatkar, Chetan Manohar, Pipaliya, Akash
Design and Development of a Novel Automatic Powershift Transmission for Battery-Electric Vehicles2025-32-009611/3/2025
The increasing adoption of battery-electric propulsion in two- and 3-wheelers, small cars, and four-wheeled delivery vehicles has created a growing demand for technological advancements to improve their autonomy. Due to cost and weight constraints, these vehicles cannot incorporate highly sophisticated electric motors, as seen in the premium car sector. Therefore, achieving the best possible efficiency in urban and extra-urban commuting requires innovative solutions. One promising approach is the integration of a two-speed transmission into the drivetrain, which allows for load point shifting within the electric motor’s operating map. This strategy significantly reduces energy consumption while maintaining optimal performance. The presented research focuses on the design and development of a simple, cost-efficient two-speed transmission that provides a viable alternative to direct drive systems. While direct drive configurations are highly efficient, they often lack flexibility in optimizing power delivery under varying load conditions. A well-designed two-speed gearbox can overcome this limitation by improving energy efficiency without adding excessive weight or complexity. However, to be a competitive solution, the transmission must achieve high efficiency and reliability while remaining lightweight and affordable. To address these challenges, a novel Auto-Powershift Transmission system has been developed and patented. This innovative system features an automatic gear-shifting mechanism that operates without any external actuators, making it inherently simple, robust, and cost-effective. By autonomously adapting to the operating conditions of the electric motor, Auto-Powershift enhances overall drivetrain efficiency, contributing to extended range and improved vehicle performance. The present work details the working principles of this technology, its design advantages, and its impact on electric vehicle efficiency. With its lightweight structure and mechanical simplicity, Auto-Powershift represents a significant step toward making propulsion systems for small and lightweight battery-electric vehicles (BEVs) more practical and efficient.
Tromayer, Juergen, Stückler, David, Kirchberger, Roland
Ultralightweight Emission Measurement Systems for Motorcycles: Accuracy and Practicality in RDE Testing2025-32-001111/3/2025
Real Driving Emission (RDE) testing for motorcycles presents unique challenges due to the motorcycle’s lightweight construction, limited mounting space, and sensitivity to added mass and aerodynamic drag. Full-functional automotive Portable Emission Measurement Systems (PEMS), while highly accurate, are often impractical for two-wheelers as their weight and size can alter driving resistances, fuel consumption, and emission profiles, but also complicate installation and probably effect the drivability of the vehicle. To address these limitations, lightweight alternatives such as Mini-PEMS and ultralightweight alternatives such as Sensor-based Emission Measurement Systems (SEMS) offer compact, low-power solutions tailored for small vehicles. SEMS are typically equipped with lower cost sensors and low-tech gas conditioning systems compared to PEMS. Due to this these systems may not meet regulatory homologation requirements. Nevertheless, they provide justifiable accuracy for many real-world applications. This paper explores the working principles and sensor technologies used in Mini-PEMS and SEMS, highlighting key trade-offs between size reduction, energy efficiency, and measurement precision. Mini-PEMS reduce complexity by employing analyzers with a minimalized conditioning system. SEMS, moreover, leverages smart sensor integration to deliver real-time emission assessments with minimal impact on vehicle dynamics. To assess their reliability, Mini-PEMS and SEMS are evaluated against laboratory-, homologation-grade equipment under controlled conditions. Accuracy analyses reveal specific limitations, but also demonstrate that these systems provide sufficiently robust data for many practical applications. By balancing accuracy with real-world feasibility, Mini-PEMS and SEMS offer a viable path for emission testing in scenarios where full-scale PEMS are impractical. Their adoption could expand the scope of RDE assessment, particularly for low-powered two-wheelers, ultimately supporting more accessible and widespread emission monitoring.
Schurl, Sebastian, Lienerth, Peter, Japs, Leonid, Schroeder, Matthias, Schmidt, Stephan, Kirchberger, Roland
Integrated Topology, Shape and Size Optimization-Application in Automotive Design and Manufacturing2025-28-037510/30/2025
CAE (Computer Aided Engineering) optimization plays a pivotal role in various industries to gain a competitive edge. CAE optimization is essential in several industries, such as automotive, aerospace and consumer electronics, etc., concentrating on enhancing component structural design. The process helps in addressing complex design challenges, including weight reduction, material usage efficiency and operational effectiveness. This paper presents applications for an integrated form shape, size and topology optimization approach of structural systems by using CAE tools. For the present study, CAD (Computer Aided Design) was prepared using CATIA V5 followed by meshing in Hyper-mesh 2022.3 version software. Optistruct was used as a solver tool. Modal analysis was performed to extract the natural frequencies of vibration and respective mode shapes. According to the results of the frequency response function study performed on the automobile air conditioning condenser, based on low-stress areas, brackets and side plates were optimized, aiming to minimize weight, improve structural strength and optimize material quantity while maintaining the component’s usefulness and safety. Therefore, the sheet metal bracket was optimized for topology and shape, and the side plate was optimized for size. Thereafter, the condenser assembly resulted in a 2.9% reduction in mass.
Mehra, Akanksha, Parayil, Paulson
SAE Truck & Off-Highway Engineering: October 202525TOFHP1010/9/2025
Lifelike simulation accelerates middle-mile autonomy The Gatik Arena platform integrates NVIDIA Cosmos models to create closed-loop, ultra-realistic digital environments that address real-world limitations. JCB heads to the front line The United States Marine Corps enlists the JCB 4CX backhoe loader as its latest recruit. Rethinking vehicle controls Smarter control architectures including CAN- and LIN-based multiplexing can elevate operational efficiency, customization and end-user experience. Editorial COMVEC covers the tech landscape Grease innovation adapts to meet new demands of heavy equipment Deutronic DC/DC converter streamlines off-highway electrification The economics of lightweighting in heavy-duty vehicles Monarch unveils AI vehicle platform ZM Trucks plants its flag in North America, pushes ahead with electric ZM8 Class 4/5 truck Product Briefs SPOTLIGHTS: Connectors; Hydraulics and Flow Control Q&A AVL addresses path to greater hybridization
The Future of EMI Shielding Is Lightweight, Flexible, and Ready for Flight25AERP09_059/1/2025
Modern military aircraft represent some of the most complex electronic environments ever engineered. These platforms integrate advanced avionics, radar systems, data links, and communication networks that must function seamlessly in hostile, high-frequency environments. In these mission-critical contexts, electromagnetic interference (EMI) poses a silent but serious threat that can degrade signal integrity, cause crosstalk between systems, or even lead to mission failure. The combination of increasing data rates, higher frequencies, and more complex electromagnetic environments demands shielding solutions that can deliver superior performance while contributing to overall system weight reduction. This challenge has driven innovation toward advanced materials that maintain electrical effectiveness while dramatically reducing mass.
Research on Multi-Material Lightweight of Electric Vehicle Battery Box13-06-02-00136/23/2025
To select appropriate lightweight materials and optimize their integration with battery enclosure components for enhanced performance and weight reduction, this study proposes a material selection strategy driven by mechanical property indices combined with the CRITIC-weighted TOPSIS method. Initially, a decision matrix incorporating bending stiffness indices was established based on the deformation characteristics of battery enclosures, focusing on commonly used metallic materials. The CRITIC-weighted TOPSIS method was employed to standardize data dimensions, determine objective weight coefficients, and calculate relative closeness coefficients for candidate material screening. Subsequently, sensitivity analysis identified critical components significantly influencing operational conditions, followed by integrated material and dimensional optimization to determine the optimal solution. The optimized battery enclosure achieved a weight reduction of 15.56 kg, with a reduction rate of 33.39%, while maintaining compliance with static/dynamic performance requirements and safety standards. This methodology demonstrates effective coordination between material selection and structural optimization in lightweight design applications.
Liu, Junfeng, Kang, Yuanchun
Multi-objective Design Optimization of a Helicopter Tail ShaftF-0081-2025-03315/20/2025
The paper describes a method for optimal design of a helicopter tail shaft that considers rotordynamic effects from long shaft assembly. The tail shaft transmits power from the main gearbox (MGB) to the tail rotor of the helicopter and operates at high speeds that may exceed 6000 rpm. While higher speeds allow for weight reduction, they also pose risks associated with supercritical operation, necessitating careful design optimization. The objective of the optimization is to maximize the first three transverse natural frequencies with the constraint of the safety parameter (avoidance of the resonance/critical zone) while minimizing the weight of the system. A Non-Dominated Sorting Genetic Algorithm (NSGA-II) is used to obtain the solution to this multiobjective optimization problem, which involves shaft design variables such as length, outer diameter, and wall thickness. In addition, the optimization framework also incorporates system related design variables, including the stiffness of tail shaft bearing supports, the location of bearings, and coupling characteristics, to comprehensively evaluate and enhance the system performance. A rotordynamics model utilizing Timoshenko beam finite elements is deployed to predict natural frequencies.
Sute, Piyush, Verma, Prashant, Mathur, Tanmay, Hajela, Prabhat
Structural Strength Evaluation of the Lightweight Frame of Bus Passenger Seat with High-Tensile Material and Analysis of the Importance of Independent Variables by Regression02-18-04-00225/10/2025
This study aims to develop a lightweight bus passenger seat frame by conducting structural nonlinear finite element analysis (FEA) on various thickness combinations of seat frame components to identify the optimal configuration. The thicknesses of critical structural members that primarily bear the load when force is applied to the seat frame were selected as independent variables, while stress on each component and compliance with ECE R14 seatbelt anchorage displacement regulations were set as dependent variables. A regression analysis was performed to calculate the importance of each component and analyze the influence of each design variable on the dependent variables. Strain gauges were attached to critical areas of the actual seat frame to conduct a seatbelt anchorage test, and simulations under identical conditions were performed using the nonlinear FEA software (LS-DYNA) to validate the reliability of the analysis results. The optimized seat frame exhibited a maximum stress of 734 MPa and a displacement of 300.5 mm, satisfying the ECE R14 compliance criteria. A total of 81 scenarios with varying thickness combinations for the seat frame components were generated, and the results of each scenario were used to analyze the importance of design variables on the seat frame’s structural strength. The regression model achieved an R2 value of 0.927, confirming its reliability in predicting the structural response. These findings contribute to the development of optimized lightweight seat frames that enhance both safety and weight efficiency in commercial vehicles.
Ko, Yeong Gook, Cho, Kyu Chun, Lee, Ji Sun, Kang, Ki Weon
Automotive fatigue Load Spectra: Modeling, Identification and Applications2025-01-82404/1/2025
Fatigue design is invariably of prior concern for the automotive industry, no matter of the evolution of the mobility market: at first because carmakers must stay compliant with general structural integrity requirements for reliability, notably applicable to the chassis system, then due to the endless competition for lightweighting in order to mitigate product costs and/or enhance vehicle efficiency. In the past, this key performance was often tackled by basic reference load cases, making use of the simplest signal content, e.g. sinus functions, to practice constant amplitude loads on test rigs and for computations, respectively. Nowadays, full time series coming from proving ground measurements, or any corresponding virtual road load data computations, may be applied to feed complex vehicle computations for virtual assessment and complex test facilities for final approval, under variable amplitude loads. In between, the concept of load spectra (i.e. distribution of amplitudes with respect of their occurrences) is here highlighted as relevant and effective to manage the load/stress generation step of the fatigue design. At first, a theoretical model is called from recent papers and detailed. Moreover, it is identified on several proving ground measurements, focusing on wheel force transducer signals. Then, a discussion on the parameters values allows to shape some general trends of the model, which is in return considered trustable for any further inference. This opens the way to two main applications: damage assessment as a function of the material/process of interest, and test acceleration making use of block-type schedules.
Facchinetti, Matteo Luca, Tjhung, Tana, Jaffre lng, Sébastien, Datta, Sandip, Hayat lng, Romain, Guo, Mingchao
Why AI-Powered Engineering Matters in Automotive Design and LightweightingTBMG-528114/1/2025
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