Volkswagen A-pillar reinforcement

Our objective was the development of a robust, integral lightweight design of a crash-relevant reinforcement element of a Golf convertible A-pillar for 3d printing. Togehter with Volkswagen Osnabrück GmbH we realized the design with the generation of a DNA based on bionic crash structures (e.g. global honeycombs, lattice structures, and local stiffening elements).
The evolution of the geometry was based on PamCrash analyzes and taking into account the AM manufacturing constraints (e.g., overhanging angles and support material).

We achieved a first-time-right design with a weight reduction from 4.1 to 1.1kg per vehicle and succeeded the crash test.

Less weight

in comparison to classical A-pillar design

Saved parts

Reduction of parts for the whole A-pillar assembly