MM4R

Recyclable multi-material design for lightweight structures

Lightweight vehicle structures are a key factor in the transition towards resource-efficient mobility. Against the backdrop of current climatic and political developments, environmental and social aspects are playing an increasingly important role alongside technical and economic criteria. In recent years, hybrid design methods have become more widely established in lightweight engineering, synergistically combining material-based, form-based and function-based lightweight design. The use of reinforced plastics in combination with steel can significantly reduce environmental impact compared to, for example, Al/Mg structures. Furthermore, the recyclability of the new materials and vehicle structures shows great potential for improved environmental performance. The combination of thermoplastic fiber-reinforced composite (FRC) hollow profiles, organio sheets and injection molding (FuPro design) is ideally suited for this purpose. With just a single material system, which is also highly recyclable (e.g. GF/PP), maximum design freedom can be achieved. Due to its integral nature, the FuPro design offers considerable economic potential compared to traditional monomaterial solutions. The project focuses on transferring this lightweight design to the application scale with the lowest possible environmental impact, taking into account all life cycle phases of the product.