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Article - Key Enabling Technologies

Lightweighting

Introduction

Lightweighting – obviously – means less mass. But it means more than that, because many lightweighting products also offer better material characteristics than conventional products. By delivering well-thought-out functional integration, by using designs that are optimised in terms of load-bearing and materials, and by deploying lighter materials, lightweighting combines modern production processes and lower costs with a sparing use of resources and enhanced functionality.

Lightweighting is a key enabling technology, because the principles of lightweighting are driving advances in technology. Weight is saved not only through the use of lighter materials, but also via the integration of functions and the use of designs that are optimised in terms of load-bearing and  materials. Since the materials and the design, the bonding techniques and the manufacturing processes are being continuously improved, the technology delivers goods with equivalent or even enhanced characteristics compared with the original product. New forward-looking markets are emerging as lightweighting combines with digitalisation and bionics.

Lightweighting is already in use in many areas today. The innovations are being driven by aerospace and the automotive and transport sectors. Each kilogram saved means an extra kilogram of payload. 100 kilograms less of weight cuts a car’s fuel consumption by around 0.5 litres per 100 kilometres, and for electric vehicles, every kilogram saved increases the range of the vehicle. In an Airbus A 320, 100 kilograms less weight means almost 10,000 litres less kerosene per aircraft and year. But the technology is also taking on an ever more important role in the construction sector, leisure and sports, the maritime industry, and medical engineering.

What is lightweighting? Enlarge

What is lightweighting?

© Lightweighting Initiative

Lightweighting cuts costs and saves resources

Producing lightweight products means using less material, and less material can mean lower costs and better properties. Using lightweight components is less energy-intensive, and leads to lower CO2 emissions. New production techniques can save further resources and energy. The various materials and lightweighting technologies can be combined in many different ways.

Lightweighting is a perfect combination of three dimensions of sustainability – economic, environmental and social. State-of-the-art, digital product development and lower-cost manufacturing is an excellent fit with a responsible approach to resources, energy and the climate, as well as with high functionality.

Facts and figures about lightweighting

44.3
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per cent
of costs in the manufacturing sector are down to materials

10,000
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litres
of kerosene are saved by an A 320 in a year if the aircraft weights 100 kg less

1,031
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lightweighting projects
are listed in the Federal Government’s funding catalogue

22
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per cent
of SMEs use lightweight materials

The future of lightweighting

New challenges facing lightweighting

Lightweighting involves a whole new level of complexity as the entire value chain needs to be organised and controlled across the whole lifecycle of a product. The fundamental changes associated with this mean that workflows and the way our work is organised are being radically transformed.

Lightweighting is a revolution that starts not with the manufacturing of a product on the shop floor but during the development stages. In general it can be said that all competitive products, irrespective of the sector in which they are being developed, will be based to some extent on lightweight structures, even if they are not explicitly “labelled”. At the same time, the revolution in manufacturing processes is one of the biggest challenges relating to this development.

New materials take time to test and almost always require new manufacturing processes. It is important for these processes to be standardised and mass production to become possible. Car-makers in particular demand high throughput rates in series production. Possible extra costs in product manufacturing must result in significant savings once the product is in use. That is the only way to justify the higher purchase price to the final consumer.

Sustainability via a circular economy

The greater the number of different materials which are joined together to make a product, the more challenging is the recovery of the recyclable materials for the manufacturing process. All of the processes from design and manufacture to use and re-use must be thought through at the initial drafting stage or the time when the product is redesigned. The aim has to be a circular economy approach which returns the valuable or even rare materials to the production process. There is a need for more research and development work in this field.

The manufacture, processing and maintenance or repair of products from new materials is challenging and demands sophisticated expertise which can only be acquired via specially designed training courses. For this reason, the teaching and handling of lightweighting methods and materials must become much more integrated into general education, vocational training and degree courses.

Despite these challenges, it is important to make the best possible use of the potential of lightweighting for the German economy. To this end, the Federal Ministry for Economic Affairs and Climate Action has launched a number of measures.

industrie 4.0

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Industrie 4.0

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The Lightweighting Initiative

Helping companies to implement lightweighting

The Federal Ministry for Economic Affairs and Climate Action supports a cross-technology and efficient transfer of expertise between the various lightweighting stakeholders around Germany. The Lightweighting Initiative serves as a central contact point for German businesses. The services are rounded off by targeted funding measures and the Lightweighting Forum.

Lightweighting is of crucial importance for the competitiveness of many sectors and the thorough modernisation of the industrial sector in Germany. For this reason, the Federal Ministry for Economic Affairs and Climate Action is continuing to expand the support available for this forward looking technology. The Lightweighting Initiative Coordination Office and the Lightweighting Forum offer expert contacts for businesses and a platform for cross-technology and cross-sectoral networking.

The contact point for businesses: the Lightweighting Initiative Coordination Office

The Lightweighting Initiative Coordination Office (Organisational Chart (PDF, 372 KB)) is a national and international network hub for German companies, and especially SMEs, supporting the implementation of lightweighting and fostering the cross-sectoral transfer of technology – with activities ranging from backing for initiatives to a more widespread industrial roll-out of lightweighting and its use in mass production.

The Lightweighting Initiative Coordination Office is a central contact point for interested stakeholders from business, science and government. It coordinates the approach to digital structural change in industry in terms of lightweighting in Germany. It provides practical recommendations and examples of best practice for companies and policymakers, as well as customised support, thus giving a decisive boost to the sector and activating suitable multipliers to get the message out. Cooperation between experts at national and international level is helping to enhance Germany’s reputation as a lightweighting centre.

A platform for transferring expertise: the Lightweighting Forum

The Economic Affairs Ministry regularly hosts a Round Table together with the Lightweighting Initiative Coordination Office. This Lightweighting Forum is a platform for a cross-technology and efficient transfer of expertise between the various stakeholders around Germany. The Forum focuses on technology trends, the activities of the Federal Government and the German Länder, and the opportunities and risks associated with foreign markets. The 9th session of the Forum will take place on September 29, 2022.
Further information can be obtained from: leichtbau@bmwk.bund.de.

Lightweighting Strategy for Germany’s industrial sector

Germany is to become the lead market and lead provider for lightweighting. Lightweighting ideally combines the three dimensions of sustainability: economy, ecology and social aspects. The BMWK's Lightweighting Strategy was developed to further strengthen this technology and set the appropriate policy framework. For this purpose, the Federal Ministry for Economic Affairs and Climate Action asked 350 experts from different industries to actively contribute their specific expertise in an extensive process and within the framework of 3 workshops from March 2019 to March 2020. Based on the impulses and fields of action contained therein, the Federal Ministry for Economic Affairs and Climate Action has developed the goals and measures for the Lightweighting Strategy for Germany as an industrial sector.

The objectives and measures of the Lightweighting Strategy for Germany as an industrial sector are to be adapted to current developments in a 3-year cycle and updated accordingly.

Funding programmes

Central Innovation Programme for SMEs (ZIM)

The Central Innovation Programme for SMEs (ZIM) is the Economic Affairs Ministry’s core programme for the market-based funding of technology for innovative German SMEs. More.

The Federal Ministry for Economic Affairs and Climate Action's Innovation Vouchers (go-inno)

The Innovation Vouchers from the Federal Ministry for Economic Affairs and Climate Action fund external management and advice from authorised consultants to help with preparing and implementing product and technical process innovations in companies with technological potential. The funding is not restricted in principle to specific technologies, products or sectors. The only precondition is that the company has fewer than 100 employees and an annual turnover of not more than €20 million. More (in German).

Start-Up funding pays off

The Federal Ministry for Economic Affairs and Climate Action is using the EXIST programme to support the establishment of high-tech start-ups in science. After a start-up is created, the German Accelerator programme provides further support for its internationalisation and market expansion. Celonis SE is a great example for the success of such activities. More.

International cooperation

Lightweight construction – leveraging international potential together

Händeschütteln vor einem Hologramm

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Climate action is the defining megatrend in society and the political arena. Innovative, resource-efficient lightweighting solutions are vital for reducing carbon emissions and achieving our climate, sustainability and electric mobility goals.

Lightweight construction means increased material and energy efficiency. At the same time, bionic structures serve as natural blueprints for industrial lightweighting applications that are developed and manufactured in digitised and networked value chains. This is both innovative and sustainable. We are therefore providing targeted support to help leverage the potential of German lightweighting.

When it comes to this crucial cross-sectoral technology, German companies – from startups and SMEs to OEMs – have a lot to offer. In order to be able to unleash the entire lightweighting potential across borders in an excellent and effective manner, it is important for companies to network well on a global scale. This is because cooperation with international players is vital for them to be able to realise joint technological innovation projects that hold major international market opportunities, and to open up new international markets and increase their competitiveness.

Services to support German companies in building international networks

Globale Welt

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The Federal Ministry for Economic Affairs and Climate Action seeks to support German companies in strengthening their international cooperation and offers a wide range of support services to help entrepreneurs build solid networks. The assistance provided by the Ministry is mainly geared to small and medium-sized enterprises (SMEs) and covers many different areas, such as business initiation, business missions, building business contacts and networking. Below is a selection of the support services available:

Market Entry Programme (MEP) of the Federal Ministry for Economic Affairs and Climate Action

Junge Menschen unterhalten sich

© iStock.com/fizkes

The Market Entry Programme (MEP) operated by the Federal Ministry for Economic Affairs and Climate Action provides project-related funding assistance to small- and medium-sized companies, especially in traditional sectors and industries (for example, in mechanical and plant engineering, in the vehicle and supplier industry, and in the chemical and electrical industries). The programme also helps the self-employed, relevant specialists from the liberal professions and providers of business-related services.

Fact-finding missions are organised to help companies explore business opportunities in challenging or new markets and market segments, often in emerging and developing economies. Local and German experts are there on the spot to provide information about market access, such as the political and legal environment, specific market opportunities and market developments, import rules, standards and taxes. They also arrange contacts to local multipliers, agencies, public institutions and business partners, as well as visits to sites and projects..

German Chambers of Industry and Commerce Abroad (AHKs)

Hand malt einen nach oben gerichteten Pfeil

© iStock.com/artisteer

As competent on-site contact partners abroad, the German Chambers of Industry and Commerce Abroad advise, support and represent German companies worldwide that want to establish or expand their business abroad. These bilateral chambers of industry and commerce are German public institutions that promote foreign trade and investment.

The close partnership of the AHKs with the Chambers of Industry and Commerce (IHKs) in Germany ensures that the needs of the business community are properly understood. Thanks to the good cooperation between the two sets of chambers at home and abroad, company enquiries can be handled directly by experts on the ground and the right solutions developed that are tailored to the market. Events organised by the Chambers of Industry and Commerce for specific countries and regions are prepared and carried out together with the respective Chambers of Industry and Commerce Abroad. The Chambers of Industry and Commerce are entities that form part of the business community’s self-management. In this role, they represent the interests of all commercial enterprises in their regions vis-à-vis local authorities, state governments, policymakers and the wider public. This creates a direct link between businesses at home and abroad. The umbrella organisation of the IHKs as well as of the AHKs is the Association of German Chambers of Commerce and Industry (DIHK).

Joint stands at trade fairs abroad - The Foreign Trade Fair Programme (AMP) of the Federal Ministry for Economic Affairs and Climate Action

Illustration von Menschen auf einer Ausstellung

© iStock.com/artisticco

The Foreign Trade Fair Programme (AMP) promotes trade fairs abroad in which the Federal Ministry for Economic Affairs and Climate Action participates in cooperation with the Association of the German Trade Fair Industry (AUMA). The trade fairs abroad supported by the Federal Ministry for Economic Affairs and Climate Action serve as an export marketing tool and enable companies to participate in joint stands at favourable conditions.

The Federal Ministry for Economic Affairs and Climate Action (BMWK) and the Federal Ministry of Food and Agriculture (BMEL) set up Foreign Trade Fair Programmes every year. AUMA represents and coordinates the interests of German industry and supports both ministries in implementing their programmes. Small and medium-sized companies in particular benefit from the joint participation when it comes to opening up foreign markets. In addition, AUMA assists its members in promoting their trade fairs abroad through the annual trade fair calendar entitled “German Trade Fair Quality Abroad” and through the AUMA trade fair database.

At www.auma.de,apotential exhibitors will find all the information they need to plan their participation in the BMWK’s Foreign Trade Fair Programme: The AUMA trade fair database contains dates, offerings and key figures for over 5,000 trade fairs in Germany and abroad. In addition, it lists the respective German contact persons for booking a particular stand at a trade fair. As an additional feature, the database includes a search function that may be used to search other foreign trade fair programmes of the Federal Government (especially for the energy and food industry) and the federal states online.

AUMA is open to suggestions for trade fairs that do not yet receive any support. Any proposals that are submitted are carefully reviewed and, if suitable, are added to the trade fair database.

For more information about the content of the Foreign Trade Fair Programme, please click here.

Programme to promote the participation of young, innovative companies in leading international trade fairs in Germany (MjiU):

Funding assistance is available for young innovative companies wishing to participate in a joint stand at leading international trade fairs in Germany. The support provided to such startups by the Federal Ministry for Economic Affairs and Climate Action enables them to market their new product and process developments with a view to opening up international markets.

For further information on the criteria and guidelines, please click here.

Germany Trade & Invest (GTAI)

In addition to promoting foreign trade and investment, Germany Trade & Invest (GTAI) also focuses on recruiting and advising foreign investors. In addition, GTAI works to enhance the image of Germany as a location for business and investment while at the same time seeking to place a focus on regions undergoing structural change and on areas affected by the coal phase-out. Companies looking for assistance in tapping into target markets will find the right support here.

Africa Business Network

The Africa Business Network and a strong network of established stakeholders and programmes to promote foreign trade and investment ensure that German firms can rely on sound advice on their way to doing business in Africa. German companies wishing to engage in Africa can draw on a bundled package of advice and support services from the Africa Business Network.

Organising and participating in international events

Mann spricht vor Publikum

© stock.adobe.com/kasto

For small and medium-sized enterprises in particular, participating in international events is an important tool for getting to know international markets, establishing important contacts and exploring possibilities for future cooperation with international partners.

JEC World Trade Fair in Paris

The JEC World is one of the world’s leading international trade fairs in the field of composite materials and their applications. It takes place every year and serves to promote forward-looking solutions and approaches as well as to present manufacturing and business opportunities within a networking platform.

United Nations Global Compact

The United Nations Global Compact is the world’s largest and most important initiative for corporate governance. Based on 10 universal principles and the Sustainable Development Goals, it pursues a vision of an inclusive and sustainable global economy for the benefit of all people, communities and markets, at present and in the future. By joining this initiative, over 15,000 companies and organisations from civil society, government and academia spanning more than 160 countries have committed themselves to making this vision a reality. In terms of lightweighting, the initiative also wants to encourage companies in the lightweighting sector to play a stronger role in multilateral forums, for example at the United Nations Global Compact 2021 Leaders Summit.

To promote these efforts, a side event on “Sustainable Lightweighting – A Game-changing Technology” was held at this year's United Nations Global Compact Leaders Summit on 14 June 2021. The event highlighted the contribution that lightweighting can make to implementing the principles of the UN Global Compact. You can find the follow-up report on the event here.

International partners of the lightweighting initiative

Weltkarte

© iStock/nadla

To connect with both international and national cooperation partners in the lightweighting sector, the interactive, digital LEICHTBAUATLAS (Lightweighting Atlas) is available in German and English. At www.leichtbauatlas.de you can create your free profile to be visible to other stakeholders and potential partners.

Cooperation between experts at national and international level is helping to enhance Germany’s reputation as a lightweighting centre and to build networks. Selected international partners are presented here in brief.

Sampe Germany e.V.
In Europe, Sampe Germany e.V. has activities in more than 25 countries, which are mainly organised through national associations – for example in France, Italy, UK, Spain, Russia, Benelux, Scandinavia and Germany.

Contact: Prof. Dr Frank Henning
Fraunhofer Institute for Chemical Technology ICT
E-Mail: frank.henning@ict.fraunhofer.de
Phone: +49 721 4640 420
Joseph-von-Fraunhofer Str. 7
76327 Pfinztal

Pôle de compétitivité EMC2
This is a European cluster for manufacturing technologies. It provides technical knowledge and expertise and brings together a community of experts to ensure lasting success for manufacturing plants.

Contact: Ms Olivia Cahn
E-Mail: olivia.cahn@pole-emc2.fr
Phone: +22 8 44 36 98
Chemin du Chaffault,
44340 Bouguenais, France

European lightweighting networks and organisations

Europakarte

© stock.adobe.com/kasto

Lightweighting associations and networks can be found all across Europe, fostering knowledge transfer between academia and industry as they seek to develop and manufacture lightweighting solutions for various industries. Selected lightweighting associations and networks in Europe are presented below.

Railway Cluster of Sweden
The Railway Cluster in Västerås is a cluster cooperation between railway technology companies in Västerås and the district of Västmanland.

Contact: Anna Wallén
E-Mail: anna.wallen@jarnvagsklustret.se
Phone: +070-824 75 59
Varmvalsvägen 11
SE-721 30 Västerås

Aerospace Cluster Sweden
A cluster for all stakeholders of the aerospace sector.

Contact: Göran Berlemo
E-Mail: goran@aerospaceclustersweden.com
Phone: +46 (0)734 18 46 52
Bröderna Ugglas Gata
581 88 Linköping

A blackboard with math formulas connected to innovation policy

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Lightweighting Atlas

Lightweighting skills in Germany at a glance

Germany is well positioned on lightweighting. Just how well can be seen from the interactive lightweighting map (the “LEICHTBAUATLAS”): it networks the individual stakeholders in research, development and applications and thus fosters the transfer of technology – across Germany and on a technology-neutral and cross-sectoral basis.

The LEICHTBAUATLAS uses an interactive website to make Germany visible as a lightweighting centre and offers businesses and scientists the possibility to network. A catalogue comprising around 250 criteria has been elaborated in close cooperation with all the key stakeholders helping people to find the right supplier or partner. A text search function and a geographical locator are also available.

The interactive website, which can be used free of charge, makes it easy to find lightweighting expertise in Germany and is open to organisations which have focused their processes and activities on lightweighting and which wish to present them to a wide audience. The LEICHTBAUATLAS takes a cross-material, cross-technology and cross-sectoral approach, and a comprehensive criteria filter permits targeted searches for suppliers or partners. Registered organisations can set up and publish their own profiles.

Skills maps of the Federal Ministry of Education and Research (BMBF)

The interactive skills maps let you research stakeholders from industry, research, training and technology transfer by region, field of application and field of technology, and to view them on easy-to-understand maps. Zooming lets you see individual Länder (federal states). Each institution is represented by a separate entry containing contact details and brief profiles of the research and work being done.

Materials map: research and innovation

Who is doing research into materials in Germany? Find an overview of research institutes and companies with their contacts here (in German).

Materials map: training

Where can I find courses and internships for materials technologies in Germany? Information and contacts can be found here (in German).

Lightweighting technologies

An overview of lightweighting

Various lightweighting technologies exist, and many can be combined with one another. By integrating different functions, by permitting designs which offer the right loads and materials, and by using lighter materials, lightweight construction can offer low-cost and flexible alternatives in many different fields.

Producing lightweight structures means using less material, and less material can mean lower costs and better properties. Lightweight materials, lightweight forms and function-integrating lightweighting complement one another to ensure that optimal use is made of raw materials, costs and energy.

Lightweight materials

Here, heavy, dense materials are replaced by lighter materials, e.g. lightweight metals (aluminium, titanium, magnesium) or composites (carbon-fibre composites (CFCs), fibreglass reinforced plastics (FRPs)). Lightweight materials are particularly efficient when, depending on the load and the function, different materials are combined. This is called hybrid or multimaterial lightweighting.

Lightweight forms

Lightweight forms are complex structures which are achieved by optimising the spatial structure (topology) of reinforcements or struts. In many cases, these are based on principles of design taken from nature and called “bionic”. Examples include the hexagonal honeycomb shape or the load-optimised structure of bones. It is often very difficult to reproduce such shapes using traditional methods like casting or milling. Modern, additive manufacturing processes like 3D printing offer the potential for entirely new shapes and designs for lighter and more efficient products.

Integrated function lightweighting

Further functions can be built into load-bearing structures. These functions then do not need to be delivered elsewhere. For example, additive processes make it possible to generate refrigerating structures in components rather than adding them onto the outside. Functional integration in lightweighting also occurs when materials that conduct electricity, such as copper or aluminium, are integrated into composites, saving the need for additional wiring. Functional integration reduces spending on materials and assembly.

Further information

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