These slides were presented at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

The integration of thin-walled structures with geometrically optimized lattice-type configurations has emerged as a promising approach for the development of crash management systems within the automotive industry. It is anticipated that these structures, when combined with advanced additive manufacturing techniques such as selective laser sintering (SLS), will exhibit superior crashworthiness, which may result in lighter and more efficient vehicle designs. This is particularly advantageous for low-volume vehicles, where the benefits of reduced weight and enhanced safety could facilitate broader adoption of this technology. This concept is currently being actively pursued in the public funded research and development project KI-LaSt*. The initial phase of this project involves the identification and development of suitable alloy candidates that can be produced using the SLS process while exhibiting the necessary ductile fracture behavior. This step is of great consequence, as it ensures that the materials used are capable of withstanding the demands of crash scenarios without compromising structural integrity. The present contribution outlines the various stages of alloy development, emphasizing rapid and straightforward testing methods that follow the inherently time-consuming production process. A substantial part of this research is dedicated to the comprehensive material characterization and identification of material parameters for the selected alloy, with an additional goal of calibrating an LS-DYNA material card. This requires a detailed analysis to comprehend the material's behavior under diverse conditions, thereby ensuring its compliance with the requisite performance standards. Moreover, the study includes structural simulations that serve to validate the calibrated material card. These simulations are indispensable for predicting the material's performance in actual crash scenarios, thus providing a robust foundation for further development and optimization. In general, the combination of thin-walled structures with optimized lattice configurations and the application of advanced manufacturing techniques, such as selective laser sintering, represents a promising advancement in automotive crash management systems. It is anticipated that the ongoing research and development efforts in the KI-LaSt project will facilitate the creation of innovative solutions that enhance vehicle safety and efficiency, particularly in low-volume production contexts. * Funds for KI-LaSt were provided by the Federal Ministry for Economic Affairs and Climate action (BMWK) due to an enactment of the German Bundestag under Grant No. 19I21036D.