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Case Study Lightweight Hinge


Additive manufactured lightweight hinge with integrated pedestrian protection

An absolutely exemplary project in the field of additive manufacturing was presented in a joint project of the company EDAG. Let yourself be inspired by what   is already possible with metal 3D printing today:


At the IAA in Frankfurt, the EDAG Group will present not only its live engineering project #collectivio but also seven technological innovations in the areas of lightweight construction and electromobility. The increasing diversity of variants, which continues to increase with alternative drive systems, requires more flexible and, above all, lighter solutions for components and likewise in production. The Wiesbaden engineering specialist EDAG has already been able to convince in recent years by its engineering skills in additive manufacturing.

This year EDAG u.a. This success story continues with its additively manufactured lightweight hood hinge. Lightweight construction expertise, electromobility, car IT and production solutions are still key topics of the future for us. I am pleased that here in Frankfurt we can once again present a firework of pro actively developed technology concepts in these future-oriented fields ", emphasizes Jürgen Vogt, CEO of the EDAG Group. At the IAA, the EDAG Group will continue its series of innovations in generatively manufactured components for use in the small series. This year, EDAG will be presenting an additively manufactured hood hinge with integrated pedestrian protection in Frankfurt.

The "LightHinge +" hinge was developed in cooperation with "voestalpine Additive Manufacturing" (Düsseldorf) and "Simufact Engineering" (Hamburg). As a result, the new development shows an ultimate weight reduction that can be produced in small batches. The lightweight structure was further developed in such a way that very low support structure requirements and thus minimal post-processing are achieved during production by means of laser beam melting through "voestalpine". In addition, the production-related thermal distortion of the component could be compensated by a pre-deformation of the geometry by means of the simulation software of "Simufact". With the help of topology optimization and the application of bionic construction principles, it has been possible to determine the minimum material requirement and, as a result, achieve a weight advantage of 50% compared to the reference.

The most interesting feature of "LightHinge +" is the integration of the active hood function. If a pedestrian collides with the vehicle, a pyrotechnic actuator from Hirtenberger (Austria) is triggered, which hits a defined area on the hinge. At this point, complex breakaway structures are monolithically integrated, which release an additional joint through the action of force and thus allow an increase of the engine hood. The impact of the pedestrian is thus cushioned by the resulting free space. The "LightHinge +" combines safety, lightweight construction and a production-friendly design.

Video zum LightHinge + Projekt EDAG


Quelle: www.edag.de   und www.simufact.de/lighthinge-plus / Youtube