iNDUVOS is a startup that emerged from the University of Wuppertal in Germany with the goal of optimizing crash-loaded structures, such as those used in car bodies to protect the occupants and components like battery packs in an accident. Our software is based on algorithms that analyze the deformations in crash simulations and selectively optimize profiles by changing their cross-sections topology, shape and thicknesses. The resulting designs meet the requirements for crash safety and use as little material as possible. Moreover, integrated manufacturing restrictions ensure that the designs are feasible. By automating and parallelizing the entire optimization process, we can reduce development times by up to 90%.

The method was originally developed for aluminum extrusion profiles, which offer many advantages for vehicle structures. Aluminum is lighter than steel, which improves fuel efficiency, maneuverability and performance. Aluminum also has a lower melting point than steel, which reduces the energy consumption in recycling. In fact, aluminum can be recycled infinitely without losing its properties, making it ideal for a circular economy. Furthermore, aluminum has superior formability, joining, and strength properties, which enable greater design flexibility and durability.

iNDUVOS and the Chair for Optimization of Mechanical Structures of the University of Wuppertal are currently collaborating with Novelis, a leading producer of flat-rolled aluminum and the world’s largest recycler of aluminum, to extend the method to roll-formed aluminum products. In this process, a long strip of sheet metal is passed through several sets of rolls that incrementally bend the sheet to the desired cross-section. It allows for production of profiles with constant cross-section in large quantities. Novelis has more than 40 years of experience in the automotive industry and has a global footprint and an innovative product portfolio. Novelis is also the world’s largest recycler of aluminum, leveraging its unique properties to deliver sustainable solutions that help automakers meet government regulations and consumer demands.

Our research partner is the Chair of Optimization of Mechanical Structures at the University of Wuppertal, which is renowned for its cutting-edge research on optimization methods for the industry. The chair contributes to the development of more material-efficient solutions and supports us with scientific expertise and resources.

Our role at iNDUVOS is to integrate the new developments for roll-formed profiles into our optimization framework and make it available to a wide range of users. We also provide the necessary support and guidance for the implementation and application of our software. Our solution is very interesting for the automotive industry, which has high production volumes and wants to accelerate the development processes and reduce their material cost to stay ahead of the competition.

The following picture shows the finite element model of a structure, that consists of several roll formed profiles, that are welded together to create a more complex cross-section. The model is created automatically by an interface between our software and a preprocessor. It uses shell elements, that are visualized with a thickness. Connections between the different profiles ensure the structural integrity during the impact. The current work of the project focuses on developing algorithms that introduce new roll formed profiles into the structure as well as rules for checking and enabling their manufacturability.