Integration of Energy Oriented Manufacturing Simulation into the Life Cycle Evaluation of Lightweight Body Parts

Antal Dér*, Alexander Kaluza, Lars Reimer, Christoph Herrmann, Sebastian Thiede

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

9 Citations (Scopus)
34 Downloads (Pure)


Recent years introduced process and material innovations in the design and manufacturing of lightweight body parts for larger scale manufacturing. However, lightweight materials and new manufacturing technologies often carry a higher environmental burden in earlier life cycle stages. The prospective life cycle evaluation of lightweight body parts remains to this day a challenging task. Yet, a functioning evaluation approach in early design stages is the prerequisite for integrating assessment results in engineering processes and thus allowing for a life cycle oriented decision making. The current paper aims to contribute to the goal of a prospective life cycle evaluation of fiber-reinforced lightweight body parts by improving models that enable to predict energy and material flows in the manufacturing stage. To this end, a modeling and simulation approach has been developed that integrates bottom-up process models into a process chain model. The approach is exemplarily applied on a case study of a door concept. In particular, the energy intensity of compression molding of glass fiber and carbon fiber sheet molding compounds has been analyzed and compared over the life cycle with a steel reference part.

Original languageEnglish
Pages (from-to)899-918
Number of pages20
JournalInternational Journal of Precision Engineering and Manufacturing - Green Technology
Issue number3
Early online date3 Jan 2022
Publication statusPublished - May 2022
Externally publishedYes


  • Compression molding
  • Energy oriented manufacturing simulation
  • Life cycle evaluation
  • Lightweight body parts
  • Sheet molding compound


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