Lightweight garage #37 Multimaterial Design @BMW 5 Series

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Lightweight garage, News

The vehicle

The BMW 5 Series has always been known for its performance, luxury and cutting-edge technology. The 2003 BMW 5 Series is a prime example of multi-material design, a technique that uses a combination of different materials to create a more efficient design. This luxury sedan features a variety of materials, including steel, aluminum and plastic, strategically placed to optimize the vehicle's performance, safety and fuel efficiency.

© Steel stove: BMW E60 525d (CC BY-SA 3.0)

The technology

The body is made from a combination of steel and aluminum, with the latter being used in areas where weight reduction is crucial, such as the hood, doors and trunk lid. This not only contributes to lower fuel consumption, but also makes the vehicle more agile and responsive on the road.

The aluminum used in the BMW 5 Series is high-strength and lightweight, making up almost 60 % of the vehicle's body structure. This material was used for the roof, hood, trunk lid, front fenders and suspension components of the vehicle. The use of aluminum in these areas helped to reduce the weight of the vehicle by approximately 25 %, which in turn led to better handling and acceleration.

The steel used in the BMW 5 Series was also high-strength and was used for the vehicle floor, doors and side panels. This resulted in greater rigidity and strength of the body, which in turn helped to improve safety and reduce noise in the interior.

The 2003 BMW 5 Series is equipped with a variety of plastic components that contribute to further weight reduction without compromising structural integrity. For example, the vehicle's front fenders and bumpers are made of high-strength plastic that absorbs shocks and does not deform in the event of an impact.

Another important aspect of multi-material design is the ability to adapt the use of materials to the respective performance requirements. In the 2003 BMW 5 Series, this can be seen in the chassis, which consists of a combination of aluminum and steel components. Again, the aluminum components are used in areas where weight reduction is critical, such as the upper control arms, while the steel components are used in areas where strength and durability are more important, such as the lower control arms.

The lightweight aspect

Overall, the 2003 BMW 5 Series was a groundbreaking vehicle in terms of design and technology. Its multi-material construction and advanced features helped set a new standard for luxury and performance, and it remains a popular car among BMW enthusiasts to this day. In addition, the use of weight-reduced materials in individual models, depending on the equipment, made it possible to achieve a weight reduction of up to 75 kg compared to its predecessor.