Materials selection for an automotive structure by integrating structural optimization with environmental impact assessment

Sustainable product development of an automotive structure requires a balanced approach towards technological, economical and ecological aspects. Current paper shows the application of a structural optimization system to the optimal choice of foams as a core material for sandwiches with aluminum alloy faces, for the use as floor panels in the bottom structure of a concept car. The minimization problem for the weight of the entire bottom structure under static load conditions, including stiffness, strength and buckling constraints, is formulated and solved for each material application. In addition to optimal (minimized) mass and materialsʹ price used for selection of foams, the assessment of an environmental impact of materials-candidates during the entire life cycle of the structure is considered.