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In the new ThyssenKrupp InCar®plus project, numerous solutions were developed for vehicle components and systems that contribute to increased efficiency through the use of new materials and advanced manufacturing technologies. These solutions are superior to current production applications in terms of weight, cost, performance and sustainability, while also meeting the demand for cost-effective weight reduction. This paper features structural components solutions focusing on Bumpers, and A- and B-pillars which overall attained between 8% to 19% weight reduction compared to their significant reference parts by incorporating flexible design concepts, progressive new materials, virtual analyses, and innovative manufacturing processes that have been tested and validated along the entire value chain. The prototypes developed were subjected to stringent safety assessments.

The ThyssenKrupp InCar Project is a comprehensive R&D development that gives automotive manufacturers modular solution kits for body, chassis and powertrain applications. The solution kits developed within this project offer weight reduction, cost savings or improved functionality. This paper will focus on the two front door solutions developed within the InCar project. The first door solution, called the Lightweight Door, achieved a 13% weight reduction. This door features a 4-piece tailored blank inner panel and a sandwich material outer panel. The second door solution, called the Advanced Door, is a completely new and innovative door architecture that uses a 2-piece tailored blank mid panel and ultra thin Dual Phase 500 outer panel to achieve an 11% weight reduction. Prototypes were manufactured and tested for both door solutions.

The ThyssenKrupp InCar Project is a comprehensive R&D development that gives automotive manufacturers modular solution kits for body, chassis, and powertrain applications. The solution kits developed within this project offer weight reduction, cost savings, or improved functionality. This paper will focus on the front longitudinal members of the body structure. The front longitudinal member is a key safety component responsible for absorbing energy in a frontal crash event. It must also have high local strength, stiffness, and fatigue resistance at the suspension attachment points. Within the InCar project, several different solutions for the front longitudinal members were developed, including stamped AHSS concepts, stamped AHSS tailored blank concepts, and tailored tube concepts using an innovative forming technology for closed section designs, called InForm T3 (Thyssen Tailored Tubes).