Overview of services

The Academy course provides a comprehensive foundation in the principles and practices of structural lightweight design. In three modules, essential topics of structural lightweight design and advanced techniques for optimizing material usage and reducing weight without sacrificing performance are taught.
This series is ideal for engineers and designers who want to deepen their understanding of lightweight construction and explore the challenges and opportunities of innovative designs.

The Academy course provides a structured approach to understanding and managing weight in engineering projects and focuses on control, optimization and risk management throughout the development cycle.
This series of courses equips experts with the necessary tools and frameworks to ensure efficient, accurate and proactive weight management in complex engineering projects.

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.

The Weight Data Tool is a software solution for methodical weight recording, analysis and evaluation across all development phases of rail vehicles. It is used to transparently and consistently analyze, predict and document mass distributions, centers of gravity and moments of inertia, secondary spring and axle loads for different rail vehicle variants. Thanks to an integrated parametric FEM module, static joint loads, spring loads and axle loads can also be analyzed for different joint configurations of rail vehicles. The software supports both top-down target weight planning and component-related bottom-up forecasting and enables efficient tracking and prediction of all weight changes, including consideration of tolerances, maturity levels, risks and weight-saving potential. It also enables strategic weight management in modular platform concepts for rail vehicles and offers extensive reporting functions for internal and external communication.

SmartACT is a specialized software for weight analysis and weight management of aircraft, spacecraft and helicopters across all development phases. It enables the structured management of mass data and supports the planning, analysis and tracking of weight distributions, centers of gravity and maturity levels of individual components. Thanks to its comparison functions, weight developments across several projects can be displayed transparently and optimization potential can be systematically identified. The software significantly reduces the workload for weight engineers and facilitates well-founded decisions with regard to costs, mass and technical risks. The software supports both top-down target weight planning and component-related bottom-up forecasting and allows all weight changes to be predicted, including consideration of tolerances, maturity levels, risks and potential weight savings. SmartACT is fully networkable, supports data exchange with common spreadsheet programs and enables traceable, version-safe documentation of all mass properties.

Software development in the context of engineering refers to the targeted creation of technical software solutions to support design, simulation and analysis processes. It is used to digitize, automate and make complex engineering processes comprehensible, for example in weight prediction, FEM analysis or data management. The focus here is on close integration with the requirements of engineers, creating interfaces to CAD, PLM or ERP systems as well as to physical-technical models. The tools developed enable precise, consistent and time-saving processing of development tasks across different specialist disciplines. Modern software development processes in engineering often follow agile methods in order to be able to react flexibly to technical changes and customer requirements.

AI-based engineering methods use artificial intelligence to automatically analyze, evaluate and optimize complex technical relationships. Algorithms such as machine learning, neural networks or evolutionary processes are used to identify patterns and optimization potential from large amounts of data. These methods support development through intelligent predictions, automatic variant comparisons and adaptive optimization processes. They are particularly effective in accelerating iterative design processes, selecting materials or identifying lightweight construction potential. They enable well-founded decisions to be made in early development phases, increase efficiency and help to ensure that objectives are achieved.

A knowledge base in the context of engineering processes is a systematically structured, digitally available knowledge system that provides development-relevant information such as materials, production technologies, calculation methods and lightweight construction potential in a structured manner. It is used to store empirical knowledge, best practices and project-specific findings centrally and make them accessible to various project participants. In development processes, the knowledge base helps to make well-founded decisions more quickly by making proven solutions accessible and avoiding redundant work. In lightweight construction in particular, it is used to select suitable materials, structures and concepts based on defined target values such as weight, rigidity or sustainability. It thus promotes efficiency and quality throughout the entire product development cycle, especially in iterative design and optimization processes.

The actual recording and verification of data in weight management during development is used for the structured recording and plausibility check of all weight-specific information such as CAD data, FEM results, material parameters and weight break-ups. The aim is to identify possible inconsistencies at an early stage and systematically eliminate them in order to create a reliable database for weight evaluation. The verification of mass properties includes checking for completeness and consistency as well as validating centers of gravity and weight distributions using specialized tools such as WDT or SmartACT. These steps are essential for identifying risks in the development process, uncovering mass potential and ensuring reliable forecasting capability. This creates the basis for ensuring controlled mass management through targeted measures in system, structural and material lightweight construction.

The top-down/bottom-up analysis of mass properties is a central instrument of weight management during development. The top-down analysis begins with the derivation of a realistic target weight from reference data such as predecessor vehicles, competitor products, technology assessments and system requirements. In contrast, bottom-up analysis is based on real development data of individual components, whereby their weights are determined in detail using parts lists, CAD models or FEM results and cumulated at system level. These two methods are systematically combined during development in order to identify deviations from the target at an early stage and to adjust the weight of each development step to the overall target in a comprehensible manner. This interaction ensures transparency, risk minimization and decision-making reliability across all phases. This ensures that mass targets are structured, controlled and adhered to in terms of balance, center of gravity and moments of inertia while complying with lightweight construction principles.

The target derivation of mass properties in the context of development-accompanying weight management refers to the systematic determination and distribution of weight requirements within a product or system to determine a target mass and the total contractual mass not to be exceeded (NTEW). It is based on a realistic, ambitious and competitive overall target weight, which is broken down top-down to component level in the early development phase and checked for plausibility and compared bottom-up in the later development phase. Functional, installation space-related and component-specific mass structures are taken into account, as well as reserves for tolerances and change risks. The aim is to ensure compliance with weight specifications through consistent definition and control of masses throughout the entire development process. Consistent target derivation forms the basis for all mass control measures, weight transparency and the development of lightweight construction potential in the sense of a holistic lightweight construction approach.

The accompanying target achievement of mass properties, aircraft-specific loads or vehicle-specific suspension and axle loads as part of development-accompanying weight management describes the systematic coordination of weight and load targets across all development phases. Target values for total mass, subsystem weights and permissible loads are defined in the early concept phases and analyzed taking tolerances, development leeway and risk reserves into account. These target values serve as guidelines for component and system design so that design measures, material selection and load path design are always in line with the targeted mass budget. Iterative checks and bottom-up forecasts based on the maturity levels of the individual components ensure that both structural integrity and functional requirements are met. The interplay of target definition, continuous verification and digitally supported mass tracking (e.g. using FEM, WDT or SmartACT) ensures transparency, controllability and a reliable basis for decision-making in the weight management process.

The control and prediction of mass properties, aircraft-specific loads or vehicle-specific spring and axle loads is a central component of weight management during development in order to make reliable statements about masses, mass distributions, centers of gravity, moments of inertia, load distributions, spring and axle loads at an early stage of development. As part of Weight & Balance, these predictions are used to systematically analyze how masses affect the behavior, safety and performance of a land vehicle, aircraft or spacecraft. The forecast is based on historical data, comparative products, analytical methods, functional weight balances, system modeling as well as simulation-based methods such as FEM analyses or CAD-based mass estimation. This early analysis enables weight targets to be defined, risks to be identified and control measures to be initiated before cost-intensive changes become necessary later on in the project. The precise prediction of mass properties and loads thus forms the basis for a robust, sustainable and economically optimized lightweight construction concept.

The control and optimization of mass properties, aircraft-specific loads and vehicle-specific spring and axle loads in the context of weight & balance and weight management during development aims to ensure that the target approach of the mass properties is within a realistic and ambitious target corridor at an early stage in order to avoid sudden, unpredictable mass developments. Both top-down and bottom-up forecasts at component level are consistently monitored and adjusted with the help of mass data, center of gravity positions, moments of inertia and load data. By constantly evaluating and monitoring these mass parameters, it is possible to influence the mass distribution, the center of gravity and the static and dynamic loads in a targeted manner, which is crucial for the function and safety of the overall system. Supported by specialized software solutions such as WDT or SmartACT, weight scenarios are simulated, deviations are identified and control measures are initiated in a targeted manner. This approach enables proactive decision-making, ensures that set weight and load specifications are achieved and ultimately increases efficiency and system performance in terms of holistic lightweight design. The sustainable development of the weight spiral is steered in the desired direction.

The reporting of mass properties, aircraft-specific loads and vehicle-specific spring and axle loads is a central component of weight management during development in the context of Weight & Balance. It serves to create transparency at all times regarding the current mass distributions, moments of inertia, centers of gravity and load variables of a product or system. The basis for this is the continuous recording, evaluation and visualization of relevant mass data throughout the development process - supported by specialized software such as WDT or SmartACT, which can also document load distributions, loads or axle loads and spring loads in a structured manner. This not only allows deviations from weight targets to be identified at an early stage, but also enables well-founded decisions to be made on technical, economic and regulatory target fulfillment. This systematic reporting makes risks visible, prepares control measures and consistently maintains the balance between lightweight construction, safety and performance.

The development and optimization of a weight management system to accompany the development process in the development area includes the creation of a customer-specific process for the continuous recording, evaluation and forecasting of masses along the entire product development process. This involves developing structured weight data models as well as forecast and target derivation models for components that take into account linear and non-linear influencing variables as well as manufacturing tolerances, uncertainties and risks. Transparent definitions of roles and responsibilities and a consistent project and risk management system enable active control of mass progression in order to secure target weights at an early stage and avoid cost-intensive corrections later on. Implementation is carried out iteratively directly in the customer's development environment and is supplemented by training to ensure independent application and further development of the process. The overall goal is holistic, cross-functional and cross-system mass data management that creates transparency at all times and forms the basis for sound technical and economic decisions.

In development-related weight management, cost analysis refers to the systematic recording and evaluation of all weight-specific costs that may arise during product development, for example due to lightweight materials, manufacturing processes or functional separation. Cost clusters are used to structure these costs along functional or component-specific groups - for example according to lightweight system design, lightweight structural design or lightweight material design - and to enable a transparent comparison of weight savings and cost impact. This classification makes it possible to specifically identify and prioritize measures with a high weight reduction at a reasonable cost. In the context of holistic lightweight construction, such analyses are carried out with the help of digital tools (e.g. WDT, SmartACT) and validated using FEM-based simulations in order to ensure technical feasibility and economic efficiency at an early stage. Ultimately, this approach forms a crucial basis for decisions on the implementation or rejection of specific lightweight construction measures.

An FEM-based CFD analysis (Computational Fluid Dynamics) uses the finite element method to precisely calculate flow behavior, pressure distributions and temperature fields in fluid-carrying systems. It enables the simulation of complex flow processes - e.g. in ducts, vehicle aerodynamics or cooling structures - under realistic boundary conditions. Geometry, material properties and flow boundaries are mapped and analyzed directly in the CAD model. Pressure losses, heat input or resistance can be minimized through targeted optimization of the flow routing, installation space distribution or surface structure. The aim is a functionally reliable, energy-efficient and weight-optimized design - ideal for holistic lightweight construction and sustainable performance.

FEM-based thermal analysis (finite element method) simulates the temperature distribution and heat transport in components under real operating conditions. It takes into account heat conduction, convection and radiation as well as specific material properties such as thermal conductivity and heat capacity. The aim is to identify hot spots at an early stage, avoid material failure due to overheating and optimize heat conduction in a targeted manner. On this basis, the geometry, choice of material or cooling strategy can be adapted to minimize thermal loads and maximize component service life. FEM-based thermal analysis is therefore a central component of structurally and material-optimized lightweight construction development.

The FEM-based analysis, design and optimization of fluid systems is used to calculate flow-induced loads and the interaction between fluids and surrounding structures. Finite element methods are used to create coupled flow and structural models in order to precisely record pressure distributions, forces, vibrations and deformations. Such simulations are particularly relevant for seals, valves, tanks, cooling systems or air and water-carrying components in vehicle, aviation and mechanical engineering. The aim is to understand the behavior in transient or stationary flows and to improve tightness, service life or efficiency through design measures. At the same time, weight, material usage and production costs can be minimized through early optimization - a significant contribution to systemic lightweight construction.

The FEM strength analysis (finite element method) is a numerical method for the computational investigation of mechanical stresses and deformations in components under various loads. It is used to simulate the structural behavior of complex geometries under realistic boundary conditions in order to identify weak points and critical areas at an early stage. The strength verification is the mathematical or experimental proof that a component can withstand the expected stresses over its service life without failure. In the combination of both methods, occurring stresses are compared with the permissible load-bearing capacity, whereby safety factors are taken into account. This is essential for ensuring safety and reliability and for implementing an economical lightweight design.

FEM-based topology optimization is a computer-aided method for structural component optimization in which the optimum material distribution across main load paths in the specified installation space is determined on the basis of load cases, boundary conditions and design objectives. The aim is to use material specifically where it is needed for force transmission and at the same time to save mass in less stressed areas. This supports holistic lightweight construction in particular, as aspects of structural lightweight construction are taken into account, whereby the focus is often on optimizing the stiffness distribution and the integration of surface support structures must be carried out separately. Stress, stiffness or frequency analyses are often integrated at the same time. This makes it possible to generate innovative topological structural lightweight construction concepts at an early stage in the development process, which specifically improve weight, costs and sustainability. The optimization process is used, for example, in the field of additive manufacturing, structural optimization of cast components, frame structures, articulated trusses and space frames as well as injection moulded components.

The aim of topography optimization is to create thin-walled structures, whereby stiffness and stress distributions or other mechanical boundary conditions remain the same or are improved. Thin-walled structures are often designed with surface structures. Here, multi-dimensional elevations, bead arrangements or dies are often used as reinforcing elements. For a given set of surface structures, topography optimization technology generates innovative design proposals with an optimal structure pattern and optimal locations for reinforcements. Typical applications include the reinforcement of cladding, shear panels, buckling stiffeners as well as the optimization of vibration behavior and NVH.

FEM stiffness optimization is a computational method for the targeted increase or adjustment of component stiffness (EI) using finite element analysis (FEM) without using unnecessary mass or material. The aim is to achieve an optimum ratio between installation space, weight and function within the specified stiffness corridor through intelligent geometry or material adjustments. In terms of holistic lightweight construction, not only is the local deformation minimized, but the stiffness-driven system effect, interface loads and influences on adjacent components are also taken into account. Stiffness optimization is often carried out via topology or shape optimization and is closely linked to mass distribution, installation space restrictions and production technologies. Typically, stiffness optimization is carried out, for example, in bending and torsionally stiff support structures.

FEM-based stress optimization is a structural optimization method that uses the finite element method (FEM) to analyse and specifically improve stress distributions in components. Bionic-based optimization methods such as SKO and special shape optimization methods are used here. - The aim is to reduce stress peaks and to design the material distribution in such a way that the existing load (strain energy distribution) is carried as evenly as possible. The geometry, wall thicknesses or reinforcements are adapted in such a way that critical stresses remain below permissible limit values. The process enables more precise utilization of material properties and contributes significantly to weight reduction in stress-driven structural systems. Stress optimization is particularly relevant in lightweight construction, as it can simultaneously improve safety, service life and resource efficiency. Stress optimization is typically performed on structures and components with local load application, bearing points, bolt-on points and systems that are subject to fatigue and vibration stresses.

FEM-based generic investigations are simulation-based structural optimization methods in which the finite element method (FEM) is used to systematically analyse the mechanical behaviour of a component under varying boundary conditions, load cases and design parameters. The aim is not only to evaluate an existing design, but also to derive fundamental interactions for optimizing the structure in terms of weight, stiffness, strength or natural frequency. Unlike classic FEM analyses, which check a defined geometry model, generic analyses use parametric geometries or topology approaches to explore variant spaces. This allows robust, load-path-compatible designs to be identified - regardless of specific installation space specifications. They are particularly suitable for the early development process, where structural potential is to be systematically tapped.

FEM crash analysis is a computer-aided method for simulating structural behavior in accidents, in which the vehicle or aircraft is digitally loaded under defined crash conditions (e.g. impact speeds, angles). Using the finite element method (FEM), the behavior of individual components and materials - such as deformation, energy absorption or failure - is calculated in detail. The aim is to meet the safety requirements for occupants, structure and system integrity as well as to demonstrate compliance with legal standards and consumer protection criteria (e.g. NCAP, EASA, FAA). Optimization is carried out through variant studies on geometries, materials and load paths, whereby topology or parameter optimization is used to specifically reduce weight and improve crash performance. Especially in lightweight construction, FEM crash analysis is essential to demonstrate safety despite lower mass and to maximize weight efficiency.

The FEM-based analysis, design and optimization of sandwich systems is carried out for various materials for cover layers and cores - such as honeycomb structures or foams. FEM analyses (finite element methods) enable the realistic evaluation of the mechanical load-bearing capacity of sandwich structures with lightweight cores (e.g. aluminum honeycombs or polymer foams) and rigid cover layers (e.g. CFRP, GFRP or metals), including hybrid composites. Material modeling is used to map different behaviors such as plasticity, buckling, damage, fatigue strength behavior or viscoelastic effects of the core materials in order to accurately predict performance under bending, shear and compression loads. Optimization strategies include topology and layer structure variations to save weight under given load cases, specifically considering the interaction of cover layer and core, where fatigue strength concepts and buckling can be considered as design criteria.

The FEM-based analysis, design and optimization of fibre composite systems - especially CFRP structures - is a key tool in lightweight structural engineering. Anisotropic material properties such as the directional dependence of stiffness and strength are precisely integrated into the finite element models using special material models. The FEM simulation enables critical load paths, stress curves and potential failure areas to be identified at an early stage in order to design structures that are appropriate for their function and load. Optimization is carried out specifically via layer structure, fibre orientation and geometry - for example by adjusting topology and layer thickness - with the aim of achieving maximum weight savings while simultaneously meeting all safety and stiffness requirements. - Such methods enable mass-efficient designs that make full use of the advantages of CFRP - such as high specific stiffness - and at the same time ensure the service life of the structure through realistic fatigue strength analyses.

In the FEM-based analysis, design and optimization for impact - i.e. impact-like or crash-like loads - scenarios such as collisions or impact events are specifically mapped using special dynamic FEM simulations. The aim is to identify structural weaknesses as early as the development phase and to optimize the design in terms of inertia-critical energy absorption, deformation behaviour and safety. Optimization is achieved through targeted modification of the geometry, material selection or topology so that maximum protection and functionality is achieved with the lowest possible weight.

FEM-based analysis, design and optimization for fatigue strength is used to ensure the fatigue safety of components under cyclic loading. Numerical methods are used to determine the stress distribution under realistic load cases. The design for fatigue strength is based on the Wöhler line method, ε-N concept / strain-life method, fracture mechanics concepts, energy and damage parameters (e.g. Smith-Watson-Topper, Morrow, Brown-Miller), linear damage accumulation (Miner rule) or other methods. Safety factors and local stresses are taken into account, taking into account the influence of medium voltage, notches, joints and material properties. The aim is to ensure that a component shows no cracks or damage after a defined number of load cycles. Optimization is carried out iteratively, e.g. through shape adaptation, material selection, topology and shape changes or bionic processes, so that the component is designed to be as light as possible but at the same time fatigue-resistant.

FEM material modeling describes the mathematical representation of the mechanical behaviour of materials such as metals, plastics, fiber composites and special materials under realistic loads. Material laws are integrated into finite element models in order to simulate anisotropic, plastic, near-failure or other material behavior that has not yet been fully researched. The aim is to predict material use and structural behavior as precisely as possible. Optimization is achieved through targeted variation of geometries, wall thicknesses or fibre orientations to reduce weight while maintaining strength and rigidity. This makes it possible to develop components that only use material where it is absolutely necessary from a structural point of view or to use the material properties specifically for structural functions - a central principle of lightweight structural engineering.

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.

Cost screening during development is a structured process for the early identification and evaluation of cost-critical components or systems within a product. The aim is to make potential cost drivers visible as early as the concept or pre-development phase and to compare them with technical requirements and lightweight construction targets. In addition to technological and manufacturing aspects, weight, material selection, functional integration and assembly costs are also taken into account. This forward-looking approach makes it possible to effectively identify optimization potential in terms of product costs as well as weight and sustainability. Cost screening is therefore an essential tool for economical and at the same time engineering-based product development.

The analysis and optimization of development and production costs includes the systematic recording, evaluation and reduction of all costs incurred during the entire product development process. The aim is to identify cost-relevant influencing factors in the early stages of development and to minimize them through targeted technical and organizational measures. Among other things, design principles, production technologies, material selection and lightweight construction potential are evaluated in order to sustainably reduce production and material costs. The use of digital tools such as CAD, FEM simulations or mass control systems helps to make the cost impact of technical decisions transparent and to exploit optimization potential at an early stage. This holistic approach enables economic benefits to be achieved without jeopardizing the functional quality and sustainability of the product.

Target costing in development is a strategic cost management approach in which a target market price and a desired profit margin serve as the starting point for deriving the maximum permissible product cost budget. This target cost budget is translated into concrete specifications for systems, assemblies and individual parts at an early stage of product development. The challenge here is to simultaneously meet technical, functional and aesthetic requirements while maintaining strict cost discipline. The development process is organized in such a way that all decisions are systematically made with a view to achieving the target costs. The aim is to realize a marketable product with an optimal cost-benefit ratio, without expensive and time-consuming iteration loops in late project phases.

Potential assessments for costs and CO₂ in the development area are based on the early identification and evaluation of lightweight construction potential in order to systematically implement structural and material savings. Holistic methods such as lightweight system analysis, structurally optimized FEM simulations and material-efficient CAD designs are used to develop design measures that not only reduce weight, but also lower production and operating costs as well as energy consumption. CO₂ savings result directly from reduced material consumption, lower energy consumption in production and use and the integration of sustainable technologies.

Technology deep dives with cost analysis in the development area are in-depth technical investigations in which individual components or systems are systematically analyzed and optimized in terms of function, structure and use of materials. Various simulation and calculation methods such as FEM analyses, topology/topography optimizations and CAD-based concept comparisons are used to identify potential for weight savings, increased performance or production simplification. This process is supplemented by a structured cost analysis in which manufacturing and follow-up costs are allocated to the respective technical variants and evaluated. The aim is to enable viable and economically feasible design decisions to be made on the basis of reliable data.

Research and analysis in technology consulting involve the methodical collection, evaluation and preparation of technical information on existing and new technologies. The aim is to identify relevant trends, materials, manufacturing processes or design principles that can contribute to solving specific technical challenges. Both market and technology data are examined and compared with internal requirements and targets. The analysis phase evaluates the technical feasibility, cost-effectiveness and innovation potential and identifies opportunities and risks for the specific application. This creates a sound basis for decision-making on development strategies, use of technology and possible lightweight construction potential.

Potential screening and analysis as part of technology consulting serve to systematically identify and evaluate technical, economic and lightweight construction improvement opportunities in products or systems. Right at the start of the project, initial ideas, sketches or concepts are examined with regard to possible savings or optimization potential using structured methods. The focus here is on evaluating feasible measures under given boundary conditions such as costs, function, production and sustainability. The analysis is carried out on the basis of functional, structural or material-related relationships, often supplemented by benchmarks, FEM preliminary estimates and knowledge databases. The aim is to quickly create a sound basis for decision-making in order to pursue the most promising approaches in a targeted manner.

An innovation workshop as part of technology consulting is a structured creative work process in which interdisciplinary teams of experts develop new solutions for technical or technological challenges. The aim is to identify entrepreneurially relevant innovation potential at an early stage, concretize it and translate it into feasible concepts. The workshop uses methodical approaches such as functional analyses, benchmarking, ideation or lightweight system construction to specifically identify new products, materials or manufacturing processes. Particular attention is paid to technical feasibility, lightweight construction potential, sustainability and economic feasibility. The result is a prioritized selection of development ideas that can be transferred to subsequent concept phases or implemented directly in the company.