What is lightweighting?

Lightweighting – obviously – means less mass. But it means more than that, because many lightweighting products also offer better material characteristics than conventional products. By delivering well-thought-out functional integration, by using designs that are optimised in terms of load-bearing and materials, and by deploying lighter materials, lightweighting combines modern production processes and lower costs with a sparing use of resources and enhanced functionality.

Lightweighting is a key enabling technology, because the principles of lightweighting are driving advances in technology. Weight is saved not only through the use of lighter materials, but also via the integration of functions and the use of designs that are optimised in terms of load-bearing and materials. Since the materials and the design, the bonding techniques and the manufacturing processes are being continuously improved, the technology delivers goods with equivalent or even enhanced characteristics compared with the original product. New forward-looking markets are emerging as lightweighting combines with digitalisation and bionics.

Lightweighting is already in use in many areas today. The innovations are being driven by aerospace and the automotive and transport sectors. Each kilogram saved means an extra kilogram of payload. 100 kilograms less of weight cuts a car’s fuel consumption by around 0.5 litres per 100 kilometres, and for electric vehicles, every kilogram saved increases the range of the vehicle. In an Airbus A 320, 100 kilograms less weight means almost 10,000 litres less kerosene per aircraft and year. But the technology is also taking on an ever more important role in the construction sector, leisure and sports, the maritime industry, and medical engineering.