Reaching new heights thanks to lightweight design – not only in the aviation sector
Most people think of the aviation sector first when they think about lightweight design, but the most important market for lightweight design products literally remains on the ground: the automotive industry. One technology in particular is picking up the pace: carbon fibre reinforced polymers.
Lightweight design reduces the ratio between the weight and the load capacity of a construction while it maintains at least the same level of functionality. In this regard most people think of the aviation sector first, but the most important market for lightweight design products literally remains on the ground: the automotive industry. High-strength steels that are used in the production of automobiles currently form the most relevant lightweight design field. However, the use of carbon fibre reinforced polymers (CFRP) in commercial vehicles is the fastest growing technological field because it growths by more than 30% every year.
A fast-paced technology: carbon fibre reinforced polymers
During the production of components, for example in the automotive industry, carbon fibres are usually immersed in epoxy resins or other resins, which cure and serve as a mould. The high production costs are the biggest problem when it comes to CFRP that are produced in this way. However, according to an estimate these costs could be decreased predominantly through automation by around 60% by 2030.
The high energy input is also being regarded critically; a temperature of up to 3,000 degrees Celsius is needed for the currently most common production process. Nevertheless, carbon fibre reinforced polymers can already be useful today. They can reduce the greenhouse gas emissions, for example, of automotive industry and of vehicles with a certain mileage: a weight reduction of 100 kg results in fuel savings of about 0.3 litres per 100 km.
The third problem lies in the reutilisation of CFRP, but it has already been solved thanks to thermo-chemical decomposition (pyrolysis). However, recycling companies must have access to catalogues containing information about the materials in the products in order to use this process.
Carbon fibres at full speed – bicycle racing and construction innovations
In bicycle racing every gram counts. Lightweight design technologies are therefore particularly interesting for world-class cyclists. For Richard Banusch, the German champion in the Madison discipline, the department “Lightweight Design with Structured Materials” of the Brandenburg University of Technology Cottbus-Senftenberg optimised his handlebar components: in comparison to the previous construction, the new components of the handlebar made out of CFRP were lighter by 44.7% and their stiffness was higher by 46.7%—and it offered considerably improved aerodynamics.
By taking a look at the share of lightweight design patents across the industries, it becomes apparent that the construction industry is the most innovative lightweight design sector. A weight reduction by 30% is nothing special in this field. Not only that: if, for example, the steel reinforcement of light concrete bridges is completely replaced by one made out of carbon fibre, the surface weight can be practically cut in half from around 600 kg/m² to 310 kg/m².
Carbon fibre-reinforced polymers are the prime example of “lightweight material design”: The traditional material steel is being replaced by one with better weight-specific properties such as aluminium or, increasingly, CFRP. Another form of lightweight design is “constructive lightweight design”. Current research focuses on meeting static requirements with fewer materials.
The outlook is bright!
One thing is for sure: lightweight design technologies are experiencing a rapid development process—and so are the sectors that use these innovations.