The selection of suitable materials in the product development process is crucial for achieving sustainability and economic goals [1]. Especially in the context of ecologically responsible and economically viable products, technical, mechanical, ecological, and economic requirements must be harmonized. In this presentation, we introduce a methodological approach for holistic material evaluation that links the early conceptual phase with data-driven decision-making processes, thereby laying the foundation for sustainable product development.

Using the development of a battery case for electric vehicles (EVs) as a case study, we illustrate how the problem can initially be abstracted to define a suitable surrogate model. The battery case development of an virtual vehicle is discussed in [2] , with reference to its virtual vehicle integration and application. The surrogate model approach simplifies the essential requirements of the component. Example concepts that can be adapted and tested include the TRIZ approach [3] and the morphological chart [4]. This model-based approach enables a mechanical assessment that considers not only the structural integrity by simplified relevant load cases but also the necessary material mass for each material option. This mechanical analysis forms the basis for an environmental assessment through Life Cycle Assessment (LCA). This holistic approach integrates multiple domains, allowing for an informed material selection process in the early development phase. As the product development progresses, the approach is continuously refined through successive steps, which can be aligned with the structured development phases described in [5].

By determining the necessary material properties and quantities, environmental impacts, such as global warming potential, can be quantified early on. This approach allows for informed, data-driven decision-making in the early development phase by making the interactions between technical, ecological, and economic criteria visible. The goal is to provide decision-makers in product development with a robust tool for making sustainable material choices.

References

[1] F. Huberth, Technologietag Leichtbau, Leichtbau BW, 2022.

[2] F. Huberth; M. Hedge, LS-DYNA Forum, 16, 2022.

[3] M. G. Moehrle; Creativity and Innovation Management, 2005, 14, 3-13.

[4] C. Schwael; F. Billing, Top 100 Management Tools, 2012, 174-176.

[5] Verein Deutscher Ingenieure (VDI), VDI 2221, 2019, 27.