Integrated computational product and production engineering for multi-material lightweight structures

André Hürkamp*, Antal Dér, Sebastian Gellrich, Tim Ossowski, Ralf Lorenz, Bernd-Arno Behrens, Christoph Herrmann, Klaus Dröder, Sebastian Thiede

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

9 Citations (Scopus)
35 Downloads (Pure)


Within product development processes, computational models are used with increasing frequency. However, the use of those methods is often restricted to the area of focus, where product design, manufacturing process, and process chain simulations are regarded independently. In the use case of multi-material lightweight structures, the desired products have to meet several requirements regarding structural performance, weight, costs, and environment. Hence, manufacturing-related effects on the product as well as on costs and environment have to be considered in very early phases of the product development process in order to provide a computational concept that supports concurrent engineering. In this contribution, we present an integrated computational concept that includes product engineering and production engineering. In a multi-scale framework, it combines detailed finite element analyses of products and their related production process with process chain and factory simulations. Including surrogate models based on machine learning, a fast evaluation of production impacts and requirements can be realized. The proposed integrated computational product and production engineering concept is demonstrated in a use case study on the manufacturing of a multi-material structure. Within this study, a sheet metal forming process in combination with an injection molding process of short fiber reinforced plastics is investigated. Different sets of process parameters are evaluated virtually in terms of resulting structural properties, cycle times, and environmental impacts.

Original languageEnglish
Pages (from-to)2551-2571
Number of pages21
JournalInternational journal of advanced manufacturing technology
Issue number9-10
Early online date11 Sep 2020
Publication statusPublished - Oct 2020
Externally publishedYes


  • Machine learning
  • Multi-material lightweight structures
  • Multi-scale simulation
  • Product development
  • Production engineering


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