Economical steel lightweight technology for body systems of the next generation

The conventional shell construction appeared in the 1970's and since then has been implemented as the "state-of-the-art" in body structure development. In order to make the vehicles of tomorrow lighter with the economical material steel, new body structure concepts must be developed, which focus on the increasing demands for lightweight concepts, along with reduced fuel consumption and the climbing requirements for crash and safety. The Auto Division of ThyssenKrupp Stahl AG through the NSB(R) project developed an innovative concept with significant lightweight potential for a body-in-white, with the benefits of innovative profiles combined with a conventional shell construction and the application of optimal steel materials. In order to make realistic comparisons throughout the project, a reference vehicle from the compact van class and produced in large series, was chosen. The NSB(R) project successfully achieved a weight reduction potential of 24%, 75 kg in the body-in-white in comparison to the reference vehicle and this achievement created no significant increase in manufacturing costs. The NSB(R) concept was checked in detail by all involved experts in regards to manufacturing and proven to be feasible.