ZIM-Project „LightConstruct“ started on 15.05.2023!
Topology optimization is crucial for the realization of lightweight and efficient structures. In doing so, this type of optimization helps to reduce material consumption and minimize environmental impact. Much lighter components are achieved through multi-material topology optimization, when optimized materials are assigned to different areas of a component. The current industry-oriented research project “LightConstruct” is concerned with the development of an effective lightweight construction process which, on the one hand, enables the achievement of weight-minimized multi-material lightweight components for the first time through direct material reduction and, on the other hand, through targeted material substitution. In contrast to current optimization methods, the new methodology should not be subject to the restriction of an upstream material selection. This is made possible by the development of a new method of numerical topology optimization (MMTO), which uses a highly efficient multi-material approach to generate an effective combination of metal and plastic materials and thus achieve a veritable weight reduction. The new methodology should take into account the manufacturing limitations of injection molding and deliver castable components. The evacuation chair as an application example is offered by the project partner ‘PH-Mechanik’. The new MMTO methodology will be applied to it to optimize the structure and weight of the evacuation chair. In addition, ‘PH-Mechanik’ works on work-packages which are related to the mechanics, manufacturing and assembly of evacuation chairs. The second project partner “Wilhelm-Plastik” helps with its know-how in the production of injection molded parts made of plastic and fiber-reinforced plastics. In addition, Wilhelm-Plastik helps to investigate the moldability of various plastic materials and to optimize the process parameters of the injection molding process.