Browse Topic: Lightweighting

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Application of topology optimization to production-ready passenger seat components design2026-01-0498To be published on 04/07/2026
Lightweighting of components has become a key challenge in the development of modern transportation systems. 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 design. However, most existing studies focus on simplified academic models, with limited demonstration in real-world applications. This paper presents a practical implementation of TO in the design of three structural components in the real-world aerospace field: seatback frame, seat fuselage mount, and seat spreader. The optimization process incorporates realistic loading conditions and boundary constraints, followed by necessary adjustments to ensure manufacturability and ergonomic compatibility, providing production-ready designs. In addition, strategies for improving stress distribution in the
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
Lightweight Wheel Design Through Shape Optimization with Structural Constraints2026-01-0504To be published on 04/07/2026
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
Yoo, Dong Yeon, Adduri, Phani, Chakravarty, Rajan
Lightweight design of a seat module assembly for a robotic arm amusement ride system using topology optimization2026-01-0481To be published on 04/07/2026
This paper presents a methodology to design a lightweight seat module assembly (SMA) for a robotic arm amusement ride, often used in dark rides. 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
Pooler, Claire, Hronowsky, Benjamin, Chai, Kevin, Shi, Yifan, Park, Taeil, Lo, David, Kim, Il Yong
From algorithm to engineering judgment: navigating topology optimization's limits in crash applications2026-01-0189To be published on 04/07/2026
The non-linear nature of crash applications has led to many designs being developed through extensive trial and error based on the intuitions of the design engineer, as such using topology optimization for crash applications can 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 optimization process of a passenger seat assembly subject to both an enforced displacement phase into a crash deceleration phase 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
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
Mechanical Performance and Deformation Mechanisms of Hybrid Cylindrical TPMS Lattices with Gradient Wall Thickness2026-01-0484To be published on 04/07/2026
Lattice metamaterials possess lightweight, high strength, and excellent energy absorption, making them promising for engineering applications. Their mechanical properties can be tuned by cell topology and structural design. This study proposes a multi-degree-of-freedom hybrid strategy for cylindrical TPMS lattices. Three uniform types (Primitive, Gyroid, IWP) were fabricated and validated through experiments and simulations. Radial, axial, and circumferential hybridizations were then explored, revealing distinct deformation and energy absorption mechanisms: CMA structures showed multi-stage behavior, while CMR and CMC offered longer plateau stages and higher stresses. Inspired by biological architectures, gradient wall thickness designs were introduced, significantly improving performance. Notably, CMR-GPI213 and CMC-PIG312 increased specific energy absorption by 24% and 14.8%, and CMA-GIP312 reduced peak force by 37.7% without sacrificing absorption. These results demonstrate that
Liu, Zhe, Guo, Pengbo, Zhong, Gaoshuo, Lian, Yuehui, Li, Youguang
Multi-Joint Topology Optimization Method with Interface Geometry Control2026-01-0503To be published on 04/07/2026
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
Shi, Yifan, Kim, Il Yong
Exploring Bionic Twisted TPMS Designs for Improved Energy Absorption2026-01-0243To be published on 04/07/2026
Triply periodic minimal surface (TPMS) lattice structures have emerged as a promising class of customizable mechanical metamaterials owing to their outstanding potential in lightweight design and multifunctional engineering applications. However, previous studies have mainly concentrated on global parameters such as wall thickness, cell size, and periodicity, while the local deformation and pre-deformation characteristics of unit cells, particularly the twist effects along specific directions, have not been systematically investigated. To address this gap, a bioinspired twisted design strategy was proposed in this study, in which controllable pre-twist was introduced along the build direction to tailor the energy absorption behavior of lattice structures. Twisted lattice specimens with different twist angles were fabricated using selective laser melting, and their mechanical properties were comprehensively examined through numerical simulations and experimental validation. The results
Liu, Zhe, Lian, Yuehui, Li, Youguang, Guo, Pengbo, Zhong, Gaoshuo
Multi-material topology optimization using difference-based equivalent static load method2026-01-0173To be published on 04/07/2026
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
Huang, Yuhao, Kim, Il Yong
Thermo-Mechanical Analysis of 1U CubeSat Structures using ANSYS: Insights for Mobility Applications2026-01-0145To be published on 04/07/2026
Particularly for small satellites like CubeSats, the growing commercialization and downsizing of space technology have brought both new opportunities and problems in the areas of heat management and structural design. A Single Unit (1U) CubeSat structure's design and simulation analysis are presented in this work, with an emphasis on the structure's mechanical and thermal performance during launch and orbit. The CubeSat platform, which is frequently constructed using commercial off-the-shelf (COTS) components, needs robust and lightweight structures that can handle mechanical loads and high temperature changes. In order to conduct mechanical stress loading (MSL) and thermal analysis (TA) on a 3D CubeSat model, this work uses ANSYS in a simulation-driven manner. Geometry modeling, meshing, boundary condition application, and simulation of important space environment elements including microgravity, solar radiation, and launch-induced stresses are all part of the process. The findings
Hussain, Muzammil, Azeem, Naqash, Adeel, Muhammad
Exploring biomimetic structures with multi-level mechanical properties to improve energy absorption2026-01-0172To be published on 04/07/2026
In this study, a class of bio-inspired three-layer twisted meta-units was proposed and systematically investigated. Parameterized models with different sequences and angles were systematically constructed through geometric twisting mapping formulas, forming multi-level mechanical response structures that combine periodicity and twisting coupling characteristics. The study focused on the effects of twisting angle, support rod diameter, and layer height sequence on mechanical properties. The results indicate that these meta-units exhibit distinct two-stage or even multi-stage plateau stresses during compression. The initial stage is primarily dominated by rotation–buckling instability induced by anti-chiral interfaces, while the later stage is governed by the curling–collapse of homo-chiral layers. In terms of sequence arrangement, the reverse–sequential arrangement mode maintains a lower first peak load while exhibiting a wider negative Poisson's ratio range and higher specific energy
Liu, Zhe, Li, Youguang, Lian, Yuehui, Zhong, Gaoshuo, Guo, Pengbo
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
Suresh, Vignesh, M, Akash, Senthilkumar, Nikil, Sundararaj, Senthilkumar, A, Garry Kiristen, Singh, Swaraj
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
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
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
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
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
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
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
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
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
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
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
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
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
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
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
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
Hatkar, Chetan Manohar, Pipaliya, Akash
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
Schurl, Sebastian, Lienerth, Peter, Japs, Leonid, Schroeder, Matthias, Schmidt, Stephan, Kirchberger, Roland
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
Tromayer, Juergen, Stückler, David, 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
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
Liu, Junfeng, Kang, Yuanchun
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
Ko, Yeong Gook, Cho, Kyu Chun, Lee, Ji Sun, Kang, Ki Weon
Lightweight Optimization of an Electric Bus Body Frame Based on the C 2 oDE Algorithm2025-01-86544/1/2025
In this work, design optimization for the lightweight of the body frame of a commercial electric bus with the requirements of stiffness, strength and crashworthiness is presented. The technique for order preference by similarity to ideal solution (TOPSIS) is applied to calculate the components that have a great impact on the output response of the static modal model and the rear-end collision model. The thickness of the five components with the highest contribution in the two models is determined as the final design variable. Design of experiment (DOE) is carried out based on the Latin Hypercube sampling method, and then the surrogate models are fitted by the least squares regression (LSR) method based on the DOE sampling data. The error analysis of the surrogate model is carried out to determine whether it can replace the finite element (FE) model for optimization, then the optimization scheme for lightweight optimization of electric bus frame is implemented based on the algorithm of
Yang, Xiujian, Tian, Dekuan, Liu, Jiaqi, Cui, Yan, Lin, Qiang
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
Facchinetti, Matteo Luca, Tjhung, Tana, Jaffre lng, Sébastien, Datta, Sandip, Hayat lng, Romain, Guo, Mingchao
Optimization Design of Bow Shaped Component Structure for Tire Scraping Machine2025-01-82944/1/2025
Using SolidWorks software's precision capabilities, an initial 3D digital model of the tire changer was constructed and then imported into Ansys for static structural analysis. By applying different meshing forms to the bow-shaped component of the tire changer and executing an exhaustive array of load simulation solutions, the total deformation and distribution of maximum principal stress of the bow-shaped component were obtained, enabling an assessment of its stress distribution and structural response under operating conditions. According to the results of the solution calculations, the total deformation and maximum principal stress distribution obtained from the hexahedral-dominated meshing method were nearly identical to those from the surface meshing method. Based on the finite element analysis results, structural optimization design was carried out on the initial 3D model of the tire changer, mainly through the reinforcement and local hollow design to achieve the increase of
Zhu, Hengjia, Gao, Yunyi, Yao, Yanan, Chao, Wang
Why AI-Powered Engineering Matters in Automotive Design and LightweightingTBMG-528114/1/2025
Lighter, recyclable body seal wins SAA award25AUTP03_083/1/2025
A lighter, colorable and fully recyclable thermoplastic body seal from Cooper Standard won the annual Innovations in Lightweighting Award given by the Society for Automotive Analysts. At the society's December meeting, Jay Murdock, senior product development engineer for Cooper Standard, accepted the award and said its FlexiCore product was designed with an eye on strong trends in what OEMs want from suppliers: sustainability, carbon neutrality, lightweighting and recyclability.
Clonts, Chris
Lattice Structure and Strut Thickness Optimization for Turbine Blade Modal Parameters01-18-01-00052/7/2025
This article explores the utilization of simple-cubic, diamond, octet-truss, and X-type lattice structures for low-pressure turbine blades in engine turbines to enhance natural frequency and decrease overall engine weight while maintaining structural integrity. The research method involves analyzing polylactic acid (PLA) hollow T106C blades with fully infilled and 50–80 location-based lattice arrangements. The study modifies the strut thickness of lattice structures using both constant and variable-based approaches and applies a generalized formula based on relative density to evaluate how changes in lattice thickness and arrangements influence natural frequencies. Furthermore, the investigation extends to multi-lattice configurations, introducing a parameter 𝑘 to signify the transition between different lattices. The modified blades were 3D printed using PLA and tested for natural frequencies through modal testing. The results demonstrate that location-based 50–80 exponential-based
Reewarabundith, Siwachai
Optimized Design and Analysis of a High-Performance, Track-Focused Quad Bike for the Indian Market2025-28-00612/7/2025
This paper presents a complete approach to the optimized design and analysis of a trach-focused quad bike suitable for the Indian market. The process of design integrates several analytical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish optimum vehicle dimensions. The primary objective is to address the unique demands of the Indian terrain and user preferences through ensure comfort, functionality, and visual appeal. The selection process for tires and suspension geometry is precisely conducted with the advanced OptimumKinematics software. This optimization provides greater performance and stability that the vehicle can accurately manage a variety of road conditions. The space frame chassis of a vehicle’s core structure features, engineered to minimalize tubing and facilitate ease of fabrication, contributing to both structural integrity and weight reduction. A robust 600cc four-cylinder engine is selected that emphasizing an optimal
Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar
Investigating Mechanical Properties of Jute Fiber and Alumina-Reinforced Epoxy Composites: Application of Taguchi and Grey Analysis for Automotive Components2025-28-01132/7/2025
Natural fiber composites (NFC’s) have considerable promise for a wide range of technological applications due to their exceptional features, which include notable weight reduction, high strength, and affordability. The aforementioned materials are also biodegradable and sustainable, which makes them appealing for use in sustainable engineering methods. This research focuses on evaluating the mechanical features of jute fiber and Al₂O₃ particle fortified polymer composites, exploring their potential for advanced engineering uses. The Taguchi technique is used with a L9 orthogonal array, integrating three-level, three-parameter approach, to systematically examine potential combinations of process variables in the manufacturing of these polymer composites. The primary goal is to optimize the mechanical attributes of the composites, which include tensile modulus, tensile stress, and weight percentage increase. Detailed investigations are conducted to interpret the effects of these process
Somsole, Lakshmi Narayana, Natarajan, Manikandan, Pasupuleti, Thejasree, Katta, Lakshmi Narasimhamu, Vivekananda, Soma
Enhancing Bumper & Headlamp Durability: Lightweight Bumper Design with Optimized Resonance Frequency2024-28-023812/5/2024
In the realm of commercial vehicle design, enhancing the durability of bumpers and headlamps is paramount for ensuring safety and reducing maintenance costs. This study explores the development of a lightweight bumper design with optimized resonance frequency to improve the durability of these critical components. The research focuses on innovative design techniques to achieve a balance between weight reduction and structural integrity. The primary objective is to minimize the impact forces transmitted to the bumper and headlamp assemblies during vibrations. By employing finite element analysis (FEA) and experimental validation, the study identifies the optimal resonance frequency that mitigates the risk of resonance-induced damage. Additionally, the study examines the influence of geometric modifications on the bumper’s performance. Various design iterations are analyzed to determine the most effective configuration for enhancing durability while maintaining compliance with industry
Pandey, Sudheer, Ganesan, Balaji
Advancing Automotive Light-weighting: Material–Process–Microstructure–Performance (MP2) Relationships of Supercritical Foam Injection of PP–Graphene Nanocomposite Foams and Over-molding13-05-03-001910/23/2024
Vehicle light-weighting constitutes a critical component in the automotive sector’s drive to improve fuel economy and reduce greenhouse gas emissions. Among the various options for lightweight materials, thermoplastic foams are distinguished by their durability, low weight, and environmental sustainability. This study explores the manufacturing of novel graphene-filled polypropylene (PP) foam, employing supercritical nitrogen as an eco-friendly substitute instead of conventional chemical foaming agents, and investigated the role of over-molding a solid skin over a foamed core on the flexural strength of the molded component. Our approach is broken down into four distinct investigations—Study I investigated the effect of different graphene content by weight percentage (wt.%), namely 0.1%, 0.5%, and 1%, on flexural properties and foam morphology obtained for 15 wt.% reduction of the PP thermoplastic, thereby helping identify an optimum graphene loading wt.%. Study II broadened the wt
Pradeep, Sai Aditya, Deshpande, Amit Makarand, Shah, Bhavik, Khan, Saida, Farahani, Saeed, Sternberg, James, Li, Gang, Pilla, Srikanth
Design Enhancement of Automotive Console Armrest Structure Utilizing Finite Element Analysis-Based Topology Optimization2024-28-000310/17/2024
This paper investigates the structural integrity of a center console armrest structure for a four-wheeler automobile. The present analysis investigates to reduce the mass of the armrest structure without compromising the structural integrity of the armrest model. Various loading conditions are employed to study the effects on the structure. Finite element analysis (FEA) approach is utilized to study the effects of various loading conditions on the structure. Topology optimization technique is employed to reduce the mass. The design criteria followed to achieve the mass reduction are kept in check by considering the global von-mises stress criterion, designable and non-designable areas of the structure. Linear structural analysis is conducted with Multipoint constraint (MPC) contacts, 3D solid higher order tetrahedral and hexahedral elements and beam elements to perform the FEA analysis. Sequential Convex Programming (SCP) method is employed in topology optimization for performing the
Shah, Viren, Shekhar, Ravi, Kushari, Subrata, Miraje, Jitendra, D, Suresh
Design and Development of a Micromobility Smart Electric Scooter to Revolutionize Urban Commuting2024-28-002110/17/2024
Urban areas around the world are facing an increasing number of issues, such as air pollution, parking shortages, traffic congestion and inadequate transit options, all of which necessitate innovative solutions. Lot of people are becoming interested in micromobility in urban areas as a replacement for quick excursions and round trips to get to or from transportation services (e.g., Offices, Institutions, Hospitals, Tourist spots, etc.). This research examines the critical role that micromobility plays, concentrating on the effectiveness of micromobility smart electric scooters in resolving urgent urban problems. Micromobility, which includes both human and electric-powered vehicles, presents a viable substitute for normal and short-distance urban commuting. This study presents a micromobility smart electric scooter that is portable and easy to operate, with the goal of transforming urban transportation. 3D model was designed using SOLIDWORKS and analyzed using ANSYS. For strength and
Tappa, Raju, Singh Chowhan, Sri Aanshu, Shaik, Amjad, Maroju, Abhinav, Talluri, Srinivasa Rao
Reducing the Weight of EV Batteries with SPECIALTY THERMOPLASTICS24AUTP10_0210/1/2024
Eight arguments for these resins, compounds and composites. Weight reduction in EV battery components is an important factor in optimizing battery energy density, which in turn is critical to extending vehicle range and boosting power and performance. Although traditional metals such as steel and aluminum are widely used in EV batteries, the ongoing push for higher energy density is opening new opportunities for thermoplastic resins, compounds, and composites. The main advantage of these materials vs. metals is their inherent lighter weight - particularly in the case of lower-density polymers. Thermoplastics can be 30-50 percent lighter than metals. They also increase design freedom, which permits further weight-out through part consolidation and thin walls.
Bobba, Somasekhar
Bemis, BASF develop lightweight hydraulic tank for compact excavators24TOFHP10_0610/1/2024
Bemis Manufacturing and BASF collaborated to develop a lighter-weight and lower-cost hydraulic tank for compact excavators that was recognized with a lightweighting award traditionally reserved for automotive innovations. Receiving an honorable mention in the Enabling Technology category of this year's Altair Enlighten Awards, the development team leveraged a combination of injection molding and vibration welding techniques to lower costs by approximately 20% and reduce mass by about 5% compared to the traditional roto-molding process. The solution also is more eco-efficient, delivering both environmental savings (reductions in lifecycle CO2 emissions) and reducing lifecycle costs.
Gehm, Ryan
Additively Manufactured Lightweight Automobile Cylinder Head—A New Process for Structural Optimization from Concept to Validated Hardware03-18-01-00039/25/2024
Reducing vehicle weight is a key task for automotive engineers to meet future emission, fuel consumption, and performance requirements. Weight reduction of cylinder head and crankcase can make a decisive contribution to achieving these objectives, as they are among the heaviest components of a passenger car powertrain. Modern passenger car cylinder heads and crankcases have greatly been optimized in terms of cost and weight in all-aluminum design using the latest conventional production techniques. However, it is becoming apparent that further significant weight reduction cannot be expected, as processes such as casting have reached their limits for further lightweighting due to manufacturing restrictions. Here, recent developments in the additive manufacturing (AM) of metallic structures is offering a new degree of freedom. As part of the government-funded research project LeiMot [Lightweight Engine (Eng.)] borderline lightweight design potential of a passenger car cylinder head with
Kayacan, Can, Pischinger, Stefan, Ahlborn, Klaus, Bültmann, Jan
SAE Truck & Off-Highway Engineering: August 202424TOFHP088/15/2024
America's first high-volume, fast-fill H2 station for HD trucks FirstElement's station at the Port of Oakland can put 100 kg of hydrogen in up to 200 trucks a day in less than 10 minutes each. Realizing software-defined commercial vehicles Continental's Georg Fässler, executive chair of the 2024 SAE COMVEC, details efforts to future-proof forthcoming vehicles. Euro NCAP details new testing for heavy-truck safety rating New tests for a Truck Safe rating scheme aim to emulate real-world collisions and encourage OEMs to fit collision avoidance technologies and improve driver vision. Gearing up a new electrified truck Eaton and BAE Systems have collaborated to create an electric powertrain featuring BAE electronics and an Eaton four-speed transmission. Editorial Hybrids are having a moment The role of a cloud-based server in service workshops Hexagon Agility and Brudeli aim to electrify CNG powertrains In pursuit of a dedicated hydrogen ICE for heavy-duty vehicles EV lightweighting via
Aitiip Integrates Freeform Injection Molding to Lower Weight and Reduce Production CostsTBMG-508606/1/2024
Pitfalls of Designing, Developing, and Maintaining Modular Avionics Systems in the Name of SustainabilityEPR20240105/7/2024
Sustainability is both an ethical responsibility and business concern for the aerospace industry. Military and commercial avionics developers have pushed toward a common standard for interfaces, computing platforms, and software in hopes of having “reusability” and reducing weight with backplane computing architectures which, in theory, would support commonality across aircraft systems. The integrated modular avionics (IMA) and military Future Airborne Capability Environment (FACE) standards are two such examples. They emerged to support common computing architectures for reuse and sustainability concepts, from the beginning of aircraft development to the sundown or mortality phase. Pitfalls of Designing, Developing, and Maintaining Modular Avionics Systems in the Name of Sustainability looks at technological, organizational, and cultural challenges making reuse and IMA platform models difficult to fully realize their sustainability goals. Additionally, it considers the certification
Reeve, Tammy
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