Simulations in Lightweight Construction and Insulation Materials

Modelling, Simulation and Optimization in Lightweight Construction

Lightweight construction is already used in a variety of ways today. In the automotive industry as well as in the construction, leisure and sports industries (e.g. sports shoe soles) and in the consumer sector (e.g. drill housings), fiber- and particle-reinforced plastics are increasingly replacing metals as materials. As both the materials and the design, joining and manufacturing processes are continuously being innovated and developed, goods with the same or even improved properties compared to the original product are created.

Lightweight construction is already being used in many different ways today. In both the automotive and consumer sectors (e.g. drill housings), fibre and particle reinforced plastics are increasingly replacing metals as a material. In the construction, leisure and sports industry (e.g. sports shoe soles), foams are increasingly being used and in the furniture industry (e.g. Billy shelves) the weight of MDF boards is being continuously reduced.

The prediction of the strength and damage behaviour of these components is complicated due to the directional dependence of the mechanical material behaviour, which is why elaborate multi-scale simulations are necessary for precise predictions. In order to reduce the high computational times, we develop model reduction methods that determine the effective material behavior, such as fatigue and damage, using microstructure simulations with FeelMath.

Example Projects


Project REVIT

Together with Fraunhofer IWM, we are working on creating microscale models. Based on these, material maps are calibrated for the mechanical characterization of fiber composites.


Efficient Multi-Scale Methods for Short Fiber Reinforced Plastics

In a cooperation with Bosch, we developed a multiscale simulation method to provide insight into the viscoelastic and fatigue behaviour of components made of short fibre reinforced polymer composites.


Characterization and Modelling of Long Fiber Reinforced Thermoplastics

We contribute our simulation expertise to the AiF project.


ResKin – Simulation of Processes in Reservoir Rock

The prediction of chemical reactions and their kinetics in reservoir rocks is the focus of the project. We support the simulation of these processes with our software tools.


Simulation Chain for Components

In several projects with Bosch, we have developed a simulation chain that takes the manufacturing process of fiber-reinforced components into account.


CustoMat 3D

The aim of the project »CustoMat 3D« is to use simulation-aided development and qualification to create custom-made aluminum alloy materials for use in laser additive manufacturing for the automobile industry.


Adaptive Approximation Methods for Multiscale Simulation of Composites

Results from the Project MuSiKo.


Simulation Fiber Boards

Together with our project partners, we develop basic principles for the production and the strength calculation of light MDF boards.


Residual Stresses in Aluminum-Silicon Cast Alloys

The project investigates Al-Si cast alloys, which are used e.g. for cylinder heads and spherical houseing.


Adhesive Connections for Plate and Slice Components

The project was designed and optimized as easy as possible for gluing connections for plate and slice components.


EU-Project ALMA

ALMA’s ambition is to develop a new type of battery-electric vehicle structure for passenger cars. The aim is to reduce the weight of the vehicle structure by up to 45 percent.

Modelling, Simulation and Optimization of Insulating Materials

Thermal or acoustic insulation materials are usually highly porous fibre or foam structures, which on the one hand should have the lowest possible thermal conductivity or high acoustic absorption, but on the other hand must also be permanently stable. The optimal selection of the material structure thus requires the determination of the different material properties and the quantitative evaluation of the conflicting criteria.

Based on microstructure simulations with GeoDict, we improve the fiber and foam structures with respect to their properties. In a second step, we can also optimize the design of multilayer systems. For the latter we also use measured input data.

Example Projects


Optimization of Doors by Means of Simulation

The demands on doors with regard to design and functionality relate to very different aspects. In various projects with the doors manufacturer Biffar, we create solutions through simulation.


Structural Optimization in Mechanics and Acoustics

The calculation of the acoustic properties - starting from the microstructure - opens up new possibilities for material optimization.


Optimization of Thermal Insulation Materials

Thermal insulation materials are highly porous fiber or foam structures. The focus of our research and development is on multi-scale modeling and simulation.