Lightweight construction in Defense

Lightweight construction and weight management in defense

In modern defense technology, the ability to react quickly, flexibly and efficiently is crucial - and this is precisely where holistic lightweight construction comes in. Holistic lightweight construction combines the three dimensions of lightweight construction - material lightweight construction, structural lightweight construction and system lightweight construction - in an overarching design approach. The aim is to consistently reduce the weight of military systems without sacrificing stability, protection or functionality. This applies equally to manned and unmanned systems.

For land vehicles, such as armored transporters or tactical vehicles, lower weight means greater mobility, greater range and reduced logistical dependencies. Lightweight structural design plays a key role here - for example through FEM-optimized load-bearing structures, high-strength aluminium or fibre-reinforced composite materials that can absorb high energy loads despite their reduced mass.

In air defense, mass control and balance are vital: aircraft, drones and helicopters are extremely sensitive to changes in weight or mass distribution. Weight-saving solutions in the primary structure (e.g. wings), but also in subsystems (e.g. avionics or armament) are crucial for flight performance, maneuverability and fuel efficiency. Here, CAD design and FEM analysis often work hand in hand with materials from aeronautical engineering, such as titanium or carbon fiber-reinforced plastic.

In the maritime domain - for surface ships and submarines - holistic weight management also leads to strategic advantages: more payload, shallower draught, better camouflage and reduced operating costs. Here, lightweight system design helps to minimize functional redundancies and shift weight at system level in a targeted manner.

Lightweight construction is a key enabler, especially for unmanned vehicles (UGV, UAV, UUV): these systems are severely limited by their energy source. Low weight allows longer ranges, longer mission durations and greater payload capacity - crucial for reconnaissance drones or autonomous underwater vehicles, for example.

Mass control and structured weight management are not just technical disciplines - they must be anchored early and interdisciplinary in the development process. After all, it is almost impossible to compensate for weight analysis that is too late. Holistic lightweight construction, supported by digital tools such as CAD and FEM, will therefore become a key factor for the efficiency, mobility and effectiveness of future defense systems - manned and unmanned, on land, at sea and in the air.