Target of the project
Weight reduction because of
 CO2 reduction
 car weighttargetgoals
 cost reduction
Result of the project
 Weight reduction 25%(original weight 12.5 kg)
 Amortization of all costs within 1 year
 Saving potentials per year 2 Mio €
Example: Maximum material removement
Standard design

hofer weightoptimised solution 


 Weight reduction up to 15%
 Cost reduction 15%
Example: Optimization of gearbox housing
FEM calculation for:
 Realization of a homogeneous stress distribution
 Durability estimations
 Evaluation of acoustical behavior

Problem analysis 
hofer solution 



Failure because of
inhomogeneous stress
distribution

Problem analysis through
simulation of the failure

Systematic solution approach
through FEM and expert analysis

Example: Aluminum versus Magnesium optimized housing
Aluminium design 
Magnesium design 


 Equal stiffness and strength
 35% less weight
 Equal manufacturing costs
Example: Rib optimization
Problem analysis 
hofer solution 


Reference project (gearbox housing):
Target:
 achieve same strength and stiffness
 achieve same acoustic behaviour
 use identical machines and assembly line
 weight reduction
Solution:
 Component with 18 % less weight, 18 % less costs, same geometrical properties
Method:
 FEM Simulation
 complete redesign
 casting simulation