At the joint exhibition stand Lightweight Technologies from Baden-Württemberg in Hall 5, C18 at Hannover Messe, the new ILO1 can be seen for the first time as a world premiere. The engineers would not have been able to build and realise the smart electric car without lightweighting due to restrictions regarding the total weight. Around the concept lightweight vehicle, 14 exhibitors from Baden-Württemberg will present their smart lightweight solutions to make products not only lighter, but also more efficient and better.

 

In order to stay in the vehicle class L7e for light electric vehicles, the car (without battery) was not allowed to be heavier than 450 kilograms. Therefore, the engineers at Emm! Solutions GmbH from Weil der Stadt used quite a lot of lightweight technology to build the ILO1. For example, the outer skin consists of a very thin CFRP laminate and many parts were made by metal and plastic 3D printing. The first four ILO1 vehicles are currently in use worldwide and number five will be presented for the first time.

 

Reduced time to market due to digital development chain 

Another key feature in the creation of the ILO is a digital process chain which allowed the prototype for the ILO1 to be developed and constructed in just four months. Accelerated Innovation GmbH is one of 14 companies which presents their lightweight solutions around the ILO1 at the joint stand. The start-up provides a platform which enables companies to use an entirely digitalised development chain to develop and optimise products much faster. “The complex simulations and feedback loops in lightweight engineering depend on digitalisation. A fully digitalised process chain can leverage the entire optimisation potential during the development phase to make parts and products not only lighter, but also more efficient and better. We are acutely aware of the interplay between lightweight construction, digitalisation and additive manufacturing which results in substantially added value,” said Dr. Wolfgang Seeliger, Managing Director, Leichtbau BW GmbH, who organised the stand with bw-i.

 

Rosswag GmbH, experts in 3D metal printing, will also be at the joint stand. One of the company’s exhibits is an additively manufactured grooving tool holder, which is cooled via internal channel structures. This is an outstanding example of the functional integration made possible by 3D printing. Parare GmbH specializes in comprehensive support in the field of industrial 3D printing. As an example, a printed steering connection can be seen at the booth, which is 60 per cent lighter than the original version. JOMATIK GmbH is exhibiting a 3D printed suction gripper in Hanover, which has now become about two-thirds lighter than the model produced by conventional technology.

Surface protection – not just for light metals 

 

C&C Bark Metall-Druckguss und Formenbau GmbH is specialised in the casting, machining and finishing of parts made of the light metal magnesium. The lightweight solutions the company offers include optical applications. Grieshaber GmbH & Co. KG works with the lightweight material aluminium and focuses on cutting and manufacturing precision components used in automotive engineering, leisure, medical products or optics. With its ceramic surfaces, ELB (Eloxalwerk Ludwigsburg Helmut Zerrer GmbH) demonstrates how surfaces – not just of light metals such as magnesium or aluminium – can be protected against wear and tear and corrosion, opening up whole new application areas for light metals such as magnesium. Surfaces are also a topic for micrometal GmbH: custom precision spare parts can be produced economically and in very high quantities with their inline etching systems. TRUMPF Laser- und Systemtechnik GmbH‘s exhibits at the joint stand include a demonstration presentation of a hybrid lightweight construction in the shape of a weight and functionally-optimised A-pillar: it has been shown that laser-based structuring processes are just as good if not better in some cases for joining purposes than are bonding agents.

 

Strong joints or lightweight core materials 

Hirschmann GmbH offers the special suspension joints, which were previously only available on request, now in their standard range. With the compact dimensions with extremely high axial and radial power transmission, the ball joints are suitable for racing, sporty vehicles and lightweight vehicles. The Deutsches MetallfaSerwerk Schwabbauer GmbH & Co. KG manufactures the so-called STAX metal fibres as endless metal fibre strands processes them into metal fibre nonwovens or metallic short fibres. Gaugler & Lutz oHG offers high quality core materials and complementary accessories for light and sandwich parts. In Hanover, they will present lightweight thermoformed several parts made of AIREX T10 and milled parts made of Rohacell, and the rigid foam PET.

 

Silent and light gears 

Weippert Kunststofftechnik GmbH manufactures screws made of plastic, which makes them up to 70 per cent lighter than their pedant made of steel. The plastic gears and gearing parts of Werner Bauser GmbH are not only up to 40 per cent lighter, but also significantly quieter in terms of noise development than conventional parts made of metal.