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6 Technologies that are Driving the Future of Lightweight Engineering

Monday August 22, 2022 at 8:00am

In industries where every millisecond and/or gram counts, there is a persistent need to minimise part weight and maximise stiffness and performance, all while reducing cost and material wastage.

The Solid Solutions Business Transformation team have been supporting our Motorsport, Engineering, and Aerospace customers with improving the strength of their parts, while minimising weight using a selection of the following 6 key technologies:

  • Cognitive Augmented Design 
  • Simulation-driven Design 
  • Reverse Engineering 
  • Composites materials 
  • Hydro-forming 
  • Stamping Die  

Cognitive Augmented Design

The new CAD. Cognitive Augmented Design is a revolutionary approach to generating and exploring lightweight shapes. 

Designers begin with functional specifications such as geometrical context, targeted performance and constraints. Concept shapes are then generated automatically using these specifications. 

Designers can then validate the structural behaviour of multiple concepts and perform trade-off studies with ease, allowing them to identify the best concept. 


Simulation-Driven Design 

Simulation-driven design optimises structures to find the best shape possible by using simulation technology earlier in the design cycle. This empowers the designers with greater knowledge and understanding of their ideas allowing them to apply earlier modifications and improvements.


Reverse Engineering

Reverse Engineering connects digital and physical worlds by digitalising existing legacy products. A physical scan reconstructs the model at the correct scale. Individual parts and components can then be optimised and reworked to produce a lighter alternative.


Composite Materials

Composite materials are ideal for combating high costs and high carbon emissions. Due to their lightweight structure, composites can increase fuel efficiency and hence reduce a vehicle's carbon footprint while providing a more durable, structurally sound part with minimal material wastage.  

When using composite materials, constraints are taken into account early in the design process for producibility checks, making it possible to define and export a complete and accurate process to the shop floor.



Hydroforming is a low-cost technology that shapes ductile metals such as aluminium and steel. Our team can support with solutions that provide feature-based modelling making it possible to design sheet metal representations in concurrent engineering.


Stamping Die

The design of stamping die tools can be achieved using formability analysis, operations planning and geometric analysis. This results in high-quality surfaces that are directly used for the Mold and Die manufacturing process.


Discover CATIA Lightweight Engineering 

The CATIA Lightweight Engineering package provides designers with the expert capabilities to minimise part weight, maximise stiffness, reduce cost and optimise material usage. To explore how each of these technologies can work in tandem, or individually to support lightweight engineering, watch our on-demand demo.


Contact Us

Complete the form to get more information or call us on 01926 333777 to speak to get in touch with the Business Transformation team today.

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