37 leading partners from research and vehicle as well as supplier industry from nine European countries have been working for four years on lightweight body-in-white structures for clean future vehicles as part of the EU SuperLIGHT-CAR (SLC) project.
The research field Lightweight and Hybrid Design Methods has made a considerable contribution to the overall concept with a front end structure which reduces weight by more than 30 percent. The optimum and intelligent use of different materials allowed for an overall weight reduction of 24 kilogrammes in comparison to the reference front end vehicle structures. Much of the weight reduction in the front end structure was achieved by the suspension strut dome consisting of a highly integrated magnesium casting. High standard requirements for crash behaviour in the front end structure also required several optimisation stages in the calculations. The DLR engineers were able to achieve excellent crash behaviour despite the weight saving in the front end structure.