Lightweight construction consulting

A potential screening is an analysis in which the lightweight design potential of parts, assemblies or complete systems is evaluated qualitatively in clusters or using percentage values based on TGM's own methods and tools as well as benchmarking procedures. Customer and product requirements as well as system, structural and material lightweight design criteria are used for this. Such an evaluation is helpful in identifying mass-saving potential in the early or late design phase and preparing a subsequent potential analysis. Potential screenings are used as part of holistic lightweight design consulting. The customer gains know-how.

A potential analysis is an analysis in which the lightweight design potential of parts, assemblies or complete systems is evaluated quantitatively as a mass-saving potential (tons, kilograms, grams) on the basis of TGM's own methods and tools as well as benchmarking procedures. Customer and product requirements as well as system, structure and lightweight material criteria and special simulation tools are used for this purpose. Such an assessment is helpful in evaluating mass-saving potential in the early or late design phase and preparing for subsequent design implementation. Potential analyses are used as part of holistic lightweight design consulting. The customer gains know-how.

A lightweight construction innovation workshop is a method for finding new ideas and solutions for a mass or lightweight construction problem. Various customer experts with different backgrounds and specialist knowledge come together to generate ideas in a structured process together with TGM experts. In an innovation workshop, the current and target statuses are analyzed, goals are defined, new suitable technologies and innovative lightweight construction ideas are presented and creativity techniques are usually applied that enable the participants to break through established thought patterns and develop new approaches. The aim of the workshop is to gain new perspectives on the problem, to collect ideas and to evaluate and develop these in joint work. The customer gains significant know-how.

The lightweight design cost analysis is a systematic procedure for evaluating the cost-effectiveness of lightweight design solutions by comparing the savings in mass and operating costs with the additional costs for materials, production or development. The aim is to find the optimum balance between weight savings and cost efficiency, taking into account the entire product life cycle. In addition to material and structural costs, aspects such as energy consumption, maintenance and sustainability are also taken into account. The lightweight construction cost analysis considers various aspects, including Material costs, development costs, manufacturing costs, life cycle costs, investment costs, potential cost savings.

The lightweight construction sustainability analysis systematically evaluates the ecological, economic and functional effects of lightweight construction solutions over the entire life cycle of a product. It not only considers the use of materials and mass savings, but also energy and resource efficiency in production, use and recycling. In terms of holistic lightweight construction, aspects from material, structural and system lightweight construction are included as well as the interactions between weight, function, carbon footprint and service life. The analysis uses tools such as life cycle assessment (LCA), mass data management and FEM-supported optimization to identify sustainable and economically viable concepts. The aim is to promote solutions that optimally combine technical performance with environmental compatibility and resource conservation.

Availability lightweight design describes the targeted selection and use of materials that are widely available, cost-efficient and can be procured at short notice in order to realize lightweight design goals even under tight project timeframes or series restrictions. In lightweight material construction, this means using familiar materials such as aluminum, high-strength steels or plastic-based composites instead of exotic or difficult-to-obtain materials, provided they meet the technical requirements. The focus here is not only on mass savings, but also on logistical and economic feasibility across the entire supply chain. This strategy enables stable production, minimizes development risks and ensures that components can be replaced or adapted quickly if necessary. Lightweight design for availability therefore makes a significant contribution to holistic mass control and sustainable lightweight construction, especially when material selection, manufacturing processes and series production maturity are optimally coordinated.

Lightweight manufacturing is a strategy within the framework of holistic lightweight construction in which the manufacturing technology itself is used specifically to reduce weight. This involves selecting or developing manufacturing processes that enable material-saving and function-integrated production - e.g. through forming techniques such as energy-efficient arch structuring or the use of additive manufacturing. The aim is not only to reduce component weight, but also to reduce the number of individual parts, which reduces assembly work, costs and interface mass. Lightweight manufacturing often has a systemic effect: through design-to-manufacturing, components can be structurally optimized and designed for production at the same time. In terms of holistic lightweight construction, lightweight manufacturing is thus closely interlinked with lightweight system construction (functional integration) and lightweight material construction (application-oriented material selection).

Competitive analysis in the context of holistic lightweight design is used to systematically evaluate products, vehicles, aircraft or spacecraft as well as their parts and components in comparison to standard market solutions in terms of mass, structure, use of materials and function. The aim is to identify holistic technical and economic lightweight design potential in comparison to the competition and to identify optimization possibilities. This involves analyzing mass properties, installation space concepts, material selection and production technologies as well as costs in order to evaluate the company's own product in terms of weight, performance and sustainability. This analysis is carried out holistically, i.e. at both system and component level, taking into account interfaces, system effects and life cycle costs. In the automotive environment, special software systems are used for competitive analysis. The results support development decisions, help with technology selection and provide valuable impetus for development.

The technology and material analysis within the framework of holistic lightweight construction serves to identify the most technically and economically suitable manufacturing processes and materials for individual components and parts. Modern manufacturing technologies such as additive processes, bionic structural designs or hybrid material systems are tested for their application potential, taking functional requirements into account. The aim is to optimally match the material properties with the loads in the component in order to reduce mass without compromising performance. At the same time, findings on recyclability, energy efficiency in production and the sustainability of the materials are included in the assessment. The analysis is always carried out in conjunction with structural and system considerations in order to harness the best lightweight construction effects as a whole.

Lightweight design strategy consulting in the context of holistic lightweight design is a systematic approach to identifying, evaluating and implementing weight-saving potential across all levels of a product or system. System, structural and material lightweight design are considered in an integrated manner in order to analyze both primary and secondary mass effects, taking into account functional, economic and sustainability-related requirements. The focus is not just on individual components, but on the entire chain of effects, including interfaces, usage contexts and production options. Consulting is carried out in close coordination with the project participants, using structured methods, benchmarking and simulation-based evaluations. The aim is to achieve the weight targets in an efficient, robust and economically viable manner through well-founded strategies and prioritized measures.