Lightweight Engineering for small and medium sized companies

Joint research project by three Saxon universities.
New research project at TU Freiberg aims to make components in lightweight technology more accessible for the Saxon industry.

Within the coming two years engineers from three Saxon Universities (TU Freiberg, TU Chemnitz and TU Dresden) together with the alliance „Leichtbau-Allianz Sachsen“ plan to develop novel digital processes for the production of tape enforced magnesium and aluminium light metal sheets. The project especially aims to provide innovations to the local industry.

Various factors and interdependences along the process chain from raw material to end product determine how effective novel light metals can be applied in industries like automotive, aviation or construction. However, those complex processes cannot be sufficiently displayed for a usage in industrial manufacturing. This is the starting point of the joint research project by the Technical Universities of Chemnitz, Dresden and Freiberg in Saxony: the scientists will investigate all steps along the process chain of thermoforming taking tape enforced, rollformed light metal sheets as an example. The so called tape is a fiber-reinforced thermoplastic strip which will be applied inline to the pre-formed light metal sheet in the new process. In this way the sheet is being reinforced leading to a significant improvement of the mechanical qualities. The development and digitalisation of technologies for the production and manufacturing of thermoplastic fibre plastic composites will be dealt with at the Institute of Lightweight Structures at TU Chemnitz. The interdisciplinary team of researchers aims to provide their results to small and medium sized companies in Saxony so that they can be validated concerning their practical application.

Simulation decrypts interdependences between raw material and processes

During previous research projects conducted within the alliance the researchers got aware that small and middle sized companies are especially missing tools for simulating and dimensioning the production of novel light metal technologies. To help provide these tools the light metal experts now plan to develop a simulation that decrypts interdependences between the respective raw material, its structural characteristics and external parameters determining the process. The data will be used to develop a digital depiction of the process which will enable the researchers to operate and predict the different process parts on their computer. The digital control method will be universally applicable and help production companies to significantly lower costs and risks for process initialization.

Joint research project by three Universities

The project named „Digitale Technologien für hybride Leichtbaustrukturen (dahlia)“ is a joint research project of three Universities in Saxony, Germany, and the alliance Leichtbau-Allianz Sachsen. Dr. Madeln Ullmann, group leader and Vice-Director at the Institute of Metal Forming at TU Bergakademie Freiberg coordinates the project on behalf of TU Freiberg. Further participants are the Institute of Lightweight Engineering and Polymer Technology of TU Dresden and the Institute of Lightweight Structures at TU Chemnitz. The joint research project runs until March 2022 and is funded with a total of 3.8 million Euros by the State of Saxony and the European Union.


Dr.-Ing. Madlen Ullmann,, +49 3731 39-3095