Based on intensive information gathering and the input of specific multidisciplinary knowledge from our project partners, we develop and build a lightweight door meeting the requirements of Original Equipment Manufacturers (OEM’s). The knowledge thus gained will also be useful for making other vehicle parts lighter.

We build expertise on both lightweight materials and joining techniques and on design and production methods. Based on this, a lightweight door concept will be developed. We aim at a weight reduction of at least 20% and the integration of more functionalities without raising the cost. We build a demonstrator and test if this door meets the requirements set by the end customer.

• Reverse engineering: gaining insight in construction and requirements
• Identification of door components and their functions
• Research into lightweight materials at component level
• Integration of the developed systems in a lightweight door concept
• Validation of the door concept

Results

• 22% weight reduction on changed parts
• Extra functionalities: “sound-box” and “heating/cooling”
• Positive validation at component, door and car level
• Technologies with high potential for weight reduction (also for other components)
• Knowledge on how to tackle the system development