Technical Path and Case Analysis of Lightweight Forward Engineering for Vehicle Development and Design C1904

The importance of weight reduction in vehicle design is well known. In recent years, OEMs have been working on vehicle lightweight research and application, particularly for new energy vehicles. Currently, many Chinese OEMs establish a lightweight target and expect that weight savings will be distributed among the vehicle’s various systems.  This tends to keep the weight reduction effort at the level of parts or partial weight loss design development and application. To be truly effective, vehicle lightweight design and development must be a top-level sequential engineering process, which is gradually distributed and implemented from top to bottom following a reasonable technical route. The Chinese automobile has experienced significant improvements in functional design, performance design, quality design, and is now moving towards robust design and lightweight sequential engineering. This course is designed to meet the needs of the OEM to teach the concept of lightweight sequential engineering and typical lightweight cases of body-in-white (BIW) parts.  In addition, the basic technical path and top-level design methods are presented through two complete cases of both a traditional vehicle and an ultra-light new energy vehicle for understanding the vehicle lightweight design process .

Learning Objectives

By attending this seminar, you will be able to:

  • Understand how to lightweight materials and processes rationally through benchmarking, comparative analysis of various materials and processes, as well as case sharing
  • Identify the lightweight design principles and evaluation methods
  • Identify the vehicle development and design path and method by the case study of typical body lightweight development cases
  • Identify the vehicle light-weighting sequential development steps and methods by the case introduction of the vehicle project management

Who Should Attend

OEM vehicle design and development, process, manufacturing or assembly engineers, vehicle integration, program management, etc.


Engineers participating in the course must have at least basic automotive product development and design experience, or R&D technical management experience; and have a certain understanding of related materials and processes.

You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

Day One
  • Automotive lightweight design and development concept;
  • Application and cases of lightweight materials on the body
    • All kinds of high strength steel
    • Magnesium alloy
    • Fiber reinforced composites
    • Performance comparison and selection principle of lightweight materials
  • Lightweight manufacturing process
    • Lightweight metal forming process
    • Glass fiber reinforced material molding process
    • Carbon fiber reinforced material molding process
    • Other lightweight molding processes
  • Lightweight design of body structure
    • Typical light-weighting cases of ultra-light new energy vehicle
    • Cases of low-cost technical solutions for comprehensive utilization of typical high-end vehicle materials
    • Typical light-weighting cases of low-cost traditional vehicle
    • Necessary tools for lightweight design
Day Two
  • Lightweight assembly design
    • Lightweight assembly design
    • Lightweight connection design
  • Integrated and platform lightweight design
    • Ideas and cases of vehicle platformization
    • Modular design concept and cases of the vehicle: front-end module design; cockpit cases, etc.
  • Vehicle lightweight top-level design technology path and cases
    • Automotive lightweight technology route
    • Vehicle lightweight and new technology application evaluation method
    • Cases of vehicle lightweight technology path design: inducing planning, target, decomposition, secondary optimization, technical solutions, process management, inspection and evaluation, etc.
    • Lightweight design cost model and multi-program comparison strategy
  • Development trend and challenge of vehicle lightweight design
Cao Du

Mr. Cao has been working in the field of automotive BIW and interior & exterior product design and development in North America for nearly 20 years. He is responsible for the design and manufacture of system lightweight, such as instrument panel system, plastic tailgate system, and front-end module integration in Ford, General Motors and Toyota.

In the past ten years after returning back to China, he has not only been responsible for the several new vehicle models’ development from cradle to launch, but also been in charge of the lightweight target achievement of weight reduction during the vehicle development. He also took the lead in the application of the automotive industry’s composite materials in vehicle lightweight. In recent years, he has published three monographs on the dimensional engineering technology and the design handbook of automotive interior and exterior. Mr. Cao has the bachelor degree of South China University of Technology and Master degree of University of Akron.

Duration: 2 Days
CEUs: 1.3

Fees: $1299.00

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