Lightweight Train Design is becoming more and more important in machinery and plant engineering but also in vehicle construction. New and hybrid materials allow considerable weight savings and result in lower operating costs.

From Research to Mass Manufacturing

When developing railway vehicles, passenger safety is a central issue setting high requirements in crash behaviour and fire protection. Thus, the choice of the manufactured material is essential. Researchers from the Department of Lightweight Design at Fraunhofer Institute for Machine Tools and Forming Technology IWU developed a new material and manufacturing concept with an excellent lightweight design potential.

Lightweight Cabin Design

In collaboration with Saxon business partners, a front lightweight cabin design for high-speed trains was developed in aluminium-foam-sandwich-design. In comparison to conventional front-end modules made of aluminium sheets, this front cabin is almost 20% lighter and offers more space for cockpit and driver while meeting the high safety requirements. This is possible due to the self-supporting sandwich construction which replaces the usually required rib structure. Since this construction is a pure metal one which can be recycled after its long term operating life, requirements on environmental sustainability and resource efficiency are met as well.

The Fraunhofer IWU provides support from concept to serial production and offers comprehensive expertise of the entire process chain: from initial draft to simulation and construction up to manufacturing and prototype creation including subsequent analysis of properties.