Lightweighting Solutions2018-11-13T13:05:32+00:00

Realizing Mass Reduction

We provide smart ideas to realize weight savings, mass reduction and performance improvements. Lightweighting offers:

  • Metal to Plastic Conversions
  • Integration of Components & Features
  • Reduction of Assembly Complexity/Secondary Operations
  • Innovation Injection Compression Technolog
  • 3D printing (Plastic & Metal)

Techniplas uses topology optimization to re-design its portfolio where applicable towards next generation of lightweighting products. One of Techniplas’ most advanced lightweighting capabilities include a tailing suspension arm which achieved a 40% weight reduction using the Techniplas Prime Instant Quoter with its proprietary built-in Topology Optimization algorithm.

Lightweight 3D Printing

We are pushing mobility forward, bringing cognitive connectivity to every layer of the vehicles that drive us forward. With 3D printing complexity is free so we can now design for greater performance while leveraging more complex designs that are simpler to manufacture.

Case Study

The Challenge

Lightweighting design by 10% and improve structural performance

  • Unique generative design technology used to redesign the existing air spring piston, which has been in production for many years and manufactured using injection molding.
  • The target of the redesign study was to reduce the weight of the piston by 10%, while preserving the functionality of the part in terms of stiffness and strength.
  • The redesign was oriented towards two manufacturing processes: 1) Injection Molding and 2) Additive Manufacturing.

Techniplas Solution

Use generative design platform to redesign for Injection Molding and Additive Manufacturing

Step 1: Identify available design space.

Step 2: Target 10% mass reduction while applying stress and deformation constraints, as well as Injection Molding manufacturability constraints.

Step 3: Verify structural performance using state-of-the-art finite element software to compare both designs.

Step 4: Manufacture both designs and compare in lab tests; use Additive Manufacturing to simplify the prototyping process.

The Challenge

Optimized design resulted in successful improvements across all dimensions.

  • 8.4% weight reduction
  • 22% Higher top-crush load capacity than the baseline

Next steps

Techniplas Prime plans to use topology optimization to redesign its portfolio where applicable towards next generation of lightweighting products.

Thin Wall Technology

  • Simulation for optimized filling situation
  • Sequential injection

Foaming

Physical / MuCell or Chemical

  • Weight reduction
  • Less deformation
  • Reduced sink marks
  • Smaller machine because of less pressure

Organo Sheets

  • Minimized wall thickness
  • Improved weight to stiffness ratio

3D Printing

  • Minimized wall thickness
  • Improved weight to stiffness ratio
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