Multi-Material Design for a Compact-Class Car Front Section

Weight reduction of a compact car’s front section was studied in this article (link). Using topology optimization, and interpreting the results in two different ways, one cost effective and one weight optimized structure is developed. Cost effective structure uses mostly steel and some Al extrusions. Weight optimized one uses lots of aluminium, steel where necessary and magnesium for strut towers. Wheelhouses in both concepts are made of plastic. Respectively %18 and %38 weight reductions are reported. Also %7 and %31 cost increase is observed.