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The concept of a structural index, λ, is developed using the simple example of a hollow beam with a cantilever load case. It is assumed that when performing material substitution, only the thickness, t, is changed. It is shown that the stiffness, K, of the beam can be defined as a function of tλ, that 1 ≤ λ ≤ 3, and that λ can be used to predict the weight savings from material substitution where stiffness is held constant. It is then demonstrated that λ can be used to predict the weight savings from material substitution in the more complex cases of the joints of a light truck cab.

This paper reports on the efforts of the initial phase of the IMPACT program to define the underlying structural theory behind selecting the proper material(s) to reduce weight in the most efficient, cost-effective manner. Following this initial phase, the IMPACT program will proceed to design and build, optimized, proprietary, full vehicle platform prototypes that achieve up to a 25 percent weight reduction total without compromising any customer-driven vehicle attributes. Most importantly, the materials and technologies selected must be implementation ready for high volume, low cost, dual-use applications. The purpose of the initial phase and an in-depth discussion on which material properties should most influence material selection are presented.