ENGENUITY
  • About Us
  • Expertise
    • Material Cards
    • Composite Consultancy
    • Automotive Engineering
    • Motorcycle Engineering
    • Design for Additive Manufacturing
  • Techniques
    • Engineering Analysis
    • Material Characterisation >
      • Crush Stress & SEA
      • Charpy Testing
      • Cyclic Shear
      • Traveller Testing
    • Equipment & Software >
      • CZone
      • Engenuity LMS
      • Equipment for Dynamic Testing
      • DIC SYSTEM
      • Printer for Automated Panel Marking
  • Case Studies
  • Contact
    • Contact Information
    • Collaboration
  • Recruitment
  • Legal Information

Case Studies

Where Knowledge Takes The Lead

Picture
We provide an unparalleled range of resources enabling organisations to...
Be effective
Reduce the cost of development
Be advanced
Incorporate the latest materials
Be agile
Shorten development time
Be innovative
Exploit advanced methods
Be efficient
Optimise your designs
Shape Divider - Style triangle_asymmetrical

SUV Lightweighting Using Affordable Composites

THERMOPLASTIC OVER-MOULDING

Vehicle Torsional Stiffness Improvement
 - Combining directional and random composites
 - Focussing stiffness where it is most beneficial
 - Part geometry development in harmony with structure
 - Thickness and layup optimisation

A Hybrid Solution:

In this project the goal was to maximise the torsional stiffness of an SUV body structure by the replacement of a pair of C-pillar reinforcement panels.  The new composite parts would replace aluminium pressings but had to remain at the same weight and crucially be cost competitive.
 
The developed solution was a short fibre carbon filled PA6 injection moulding which incorporated local continuous fibre reinforcements.  Predictive analysis was used to optimise the location, extent and layup (fibre direction) of the reinforcements so that the minimum amount of ‘premium’ material was used whilst achieving a significant performance uplift.
 
The result was an improvement of 7% on the overall torsional stiffness of the vehicle body structure.  With the new parts and process, production rates were achievable, cost was comparable, and there was no weight penalty.
Picture
Picture

BAC Mono Chassis Development

OPTIMISING FOR PERFORMANCE

Further improvements on an optimised design
 - 18% weight reduction
 - Improved roll over protection
 - Maintains stiffness and durability

​High Performance Steel Structure

Working with BAC, this project aimed to re-engineer the Mono supercar’s space frame, tubular chassis using a niobium enhanced steel. Engenuity started with data acquisition, instrumenting the car during high speed testing to benchmark existing chassis performance. 

Using Engenuity’s on site material laboratory, the niobium microalloyed steel was characterised with material cards generated for accurate simulation. Engenuity’s engineering team then used their decades of experience of race car and supercar development to optimise the chassis against multiple load cases. This expertise led to a mass reduction of 18% from a chassis that had already been designed for minimal weight by automotive experts. Achieved working within strict constraints in terms of packaging and manufacturing tooling, the new chassis also maintained durability and torsional stiffness while improving roll over protection. 
Picture
Shape Divider - Style triangle_asymmetrical

Together we set the standards of excellence
​for engineering design development

UK
Unit 7, Paynes Place Farm
Cuckfield Road, Burgess Hill,
West Sussex, RH15 8RG, UK
+44 (0)1444 457 257
enquiry@engenuity.net
Spain 
Paseo de Gracia, 97
5º 1ª , Barcelona,
08008, Spain
+34-938328227
​enquiry@engenuity.net
Germany
Melissenweg 8
86169 Augsburg,
Germany
+49-1759092434
enquiry@engenuity.net
Picture
© COPYRIGHT 2020. ALL RIGHTS RESERVED/
​ LEGAL INFORMATION.
  • About Us
  • Expertise
    • Material Cards
    • Composite Consultancy
    • Automotive Engineering
    • Motorcycle Engineering
    • Design for Additive Manufacturing
  • Techniques
    • Engineering Analysis
    • Material Characterisation >
      • Crush Stress & SEA
      • Charpy Testing
      • Cyclic Shear
      • Traveller Testing
    • Equipment & Software >
      • CZone
      • Engenuity LMS
      • Equipment for Dynamic Testing
      • DIC SYSTEM
      • Printer for Automated Panel Marking
  • Case Studies
  • Contact
    • Contact Information
    • Collaboration
  • Recruitment
  • Legal Information