CAD concept modelling in the installation space or package is used in the early stages of development to visualize technical concepts in three dimensions and ensure their installability and interfaces at an early stage. It enables the rapid creation and adaptation of digital volume models to assess installation space conflicts, positioning options and assembly accessibility. Variants of components or systems are developed to ensure optimum integration in terms of function, ergonomics, ease of servicing and weight. This phase is crucial in order to systematically consider structural, functional and thermal constraints and achieve a balanced architecture. CAD concept modelling thus lays the foundation for robust, weight-optimized and production-oriented product development.

CAD concept design in holistic lightweight construction is used in the early phase of product development to design digital solution variants with minimum weight and maximum functionality as early as possible. It combines systemic, structural and material-related lightweight construction principles in an integrated design approach that already takes interfaces, effective surfaces and mass distributions into account. By incorporating FEM analyses, material models and manufacturing processes at an early stage, potential weight drivers and risks can be identified and specifically avoided. This enables rapid convergence to weight-optimized, production-ready designs with a high level of development maturity. CAD concept design thus forms the basis for effective mass management and the sustainable implementation of ambitious lightweight construction goals.

CAD prototype design is a digitally supported design process for developing realistic, functional component or system models that are used for tests, validations and test setups. In contrast to concept design, the focus here is on a high level of detail, complete geometry and production-ready design, including all necessary tolerances, interfaces and assembly points. It is used for the virtual preparation of physical prototypes and helps to save time and costs by identifying design weaknesses at an early stage. CAD prototype design is particularly important in lightweight construction in order to specifically safeguard weight-saving measures and prepare components for FEM analyses and crash simulations. It also forms the bridge to industrialization, as it supports the transition to production drawings, tool design and digital twins.

CAD design for sheet metal forming is a specialized development process in which components are designed in such a way that they can be manufactured efficiently and appropriately for the material using forming processes such as deep drawing, bending or stamping. The specific properties of the sheet material, such as flow behavior, springback and minimum bending radii, are already taken into account in the virtual modeling. The CAD models not only serve as a geometry template, but also as a basis for simulation analyses of formability and process reliability. The aim is to produce functional, production-ready components that are as light as possible and can be manufactured economically. The close integration of design, simulation and production specifications results in high component quality with reduced material usage.

CAD design for cast components involves the digital modeling of components that are later manufactured using the casting process. Special casting requirements such as draft angles, wall thickness tolerances, riser positioning and demoldability must already be taken into account during the design phase. The aim is to create a geometrically and functionally optimized mould that can withstand the loads and make the casting technology economically feasible. The integration of FEM pre-analyses is particularly important in order to identify critical areas in terms of strength, rigidity and thermal behavior at an early stage. CAD modeling allows the entire process chain - from tool design to initial sampling - to be efficiently prepared and controlled.

CAD design for extruded profiles and extruded components includes the geometric design and digital modeling of components that are manufactured using continuous or punch-based forming processes. This involves developing functional cross-sectional geometries that are adapted to the respective process in terms of both material and production. Particular attention is paid to uniform wall thickness distribution, minimization of material accumulation and optimum alignment with load paths. The CAD models are not only used as a basis for FEM analyses for component evaluation, but also to ensure manufacturability and for communication with tool and manufacturing partners. The aim is to realize a lightweight component design that offers high structural strength with minimal material usage.

CAD design for welded structures describes the digital development of assemblies that are joined by welding, whereby the special requirements for joints, distortions and manufacturing tolerances are already taken into account in the virtual model. The aim is to design load-bearing structures suitable for production that are both stable and economical to manufacture. Weld seams, stress flows and component thicknesses are specifically positioned and designed, taking material properties and manufacturing processes into account. The design is carried out in 3D in order to realistically depict the installation space, mountability and welding sequences and to carry out collision tests at an early stage. This approach allows lightweight construction potential to be efficiently exploited through functionally appropriate material distribution, targeted load path management and optimized geometries.

CAD concept design in the context of generic AI-based model generation describes the use of artificial intelligence for the automated development and evaluation of initial design drafts based on predefined framework conditions. Geometric models are generated generatively, taking into account functional requirements, installation space specifications and production-related boundary conditions. The AI supports a wide range of variants through intelligent suggestion logic and comparability, significantly accelerating the concept development process. Thanks to the connection to simulation tools, generated concepts can be analyzed directly with regard to lightweight design criteria such as mass, stiffness or stress. This creates a data-driven, iterative development process that opens up the potential for holistically optimized and mass-optimized design solutions.

Production-oriented CAD design refers to the design process in which components and assemblies are designed in such a way that they can be produced economically, safely and reliably. Manufacturing processes, tolerances, tools, joining methods and material properties are already taken into account in the digital model. The aim is to avoid collisions, time-consuming reworking or costly production steps while ensuring high product quality. The design is carried out in close coordination with production in order to optimize ease of assembly, automation potential and unit costs. This approach is particularly crucial in lightweight construction, as it is the only way to efficiently realize complex, weight-optimized structures.