Dynamics & Lightweight Construction
Less mass.
More dynamism.
Lightweight and structural modules for highly dynamic robotics, automation and industrial applications with the highest demands on movement, stiffness and efficiency.
Areas of application
Robotics · Automation · Medical Technology
BENEFITS FOR YOUR APPLICATION
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reduced moving system masses
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higher dynamics & clock speed
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structurally integrated functional interfaces
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stiffness-optimized structures
up to
+15%
faster cycle times
up to
+13%
longer service life
up to
-6%
Energy consumption
Fewer interfaces. Faster implementation.
Development, integration and industrialization of complex structural, lightweight and functional systems for mechanical engineering, robotics and industrial applications.
System Architecture & Integration
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Technical concepts for structural and functional assemblies
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Space, load and integration analyses
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Interface, packaging and system architecture
Development & Design
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Development of complex lightweight and multi-material assemblies
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Structural, housing and functional integration
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FEA simulation, functional and load validation
Prototype construction & validation
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Functional prototypes and technical demonstrators
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Testing, stress tests and validation
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Integration of mechanical, electrical and functional systems
Industrialization & Small Series Production
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System development suitable for manufacturing and assembly
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Quality assurance and technical documentation
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Small-batch production-ready structural and integration solutions
Use Case 01: Functionally Integrated Multi-Material Assembly
Gripper housing in lightweight construction
Challenge
A lightweight, rigid and functionally integrated gripper housing was required for a highly dynamic production plant.
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Integration of electronics, cable systems and mechanical components
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high dynamics, stiffness and installation space requirements
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protected and virtually enclosed guidance of sensitive peripherals
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Lack of composite and multi-material expertise at the customer's site
Solution
VELA developed and delivered a ready-to-assemble multi-material assembly as a fully integrable system solution .
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CFRP metal housing with high stiffness and low weight
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Integration of cables, connectors and functional components within the structure
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Development for manufacturability including design, strength analysis and industrialization
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pre-assembled module instead of complex individual part integration
Result
The customer received a fully integrated system assembly from a single source – including development, supplier management and final assembly.
Customer benefits:
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No additional supplier coordination required
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Maximum usable interior space thanks to thin-walled CFRP structure
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protected and neatly integrated cable and function routing
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simplified assembly and faster integration into the overall system
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reduced moving masses combined with high structural stiffness
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higher dynamics and increased cycle time of the system
Leichtbau
Carbon-Monocoque & Spaceframe-Rahmen
Fahrwerk
Pushrod-Fahrwerk für maximale Fahrdynamik
TOTAL VEHICLE
Entwicklung & Projektkoordination
KLEINSERIE
Prototypen- & Serienvorbereitung
up to
20%
higher clock speed of the overall system
up to
33%
more construction space
up to
48%
faster final assembly
Use Case 02: Housing and structure development for medical technology
Neonatal transport incubator for mobile use
Challenge
A safe, hygienic and mass-producible housing system for medical technology use had to be developed for a portable baby incubator.
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high demands on safety, hygiene and reliability
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complex housing and structural components
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Approval and documentation requirements
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economic implementation up to series production
Solution
VELA developed and industrialized the complete housing and structure concept as a regulatory-compliant system solution.
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Development of housing, structural and connecting elements
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Strength calculation and technical validation
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Design suitable for manufacturing and assembly
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Supplier management and industrialization
Result
The customer received a production-ready and approval-oriented system solution from a single source – from design to industrialization.
Customer benefits:
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one central contact person instead of several suppliers
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Approval-oriented development from the outset
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Support with technical documentation and verification
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hygienic, easy-to-clean and serviceable assemblies
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safe and economical series production
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rapid industrialization and market launch
Leichtbau
Carbon-Monocoque & Spaceframe-Rahmen
Fahrwerk
Pushrod-Fahrwerk für maximale Fahrdynamik
GESAMTFAHRZEUG
Entwicklung & Projektkoordination
KLEINSERIE
Prototypen- & Serienvorbereitung
Less coordination effort .
One partner instead of several suppliers.
Increased product safety.
Through approval-oriented development.
Faster time to market.
Through integrated development and industrialization.
TECHNICAL QUESTIONS. CONCRETE ANSWERS.
Special-purpose vehicles are developed wherever standard production vehicles reach their technical or functional limits. Depending on the application, requirements for chassis, body, weight, integration, and certification vary considerably. A development partner should therefore be proficient in both different vehicle platforms and industry-specific requirements.
VELA develops components, assemblies and vehicle systems for, among others:
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Special and municipal vehicles
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Emergency and rescue vehicles
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Caravans and leisure vehicles
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Defense and security vehicles
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Commercial vehicles and special bodies
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Technology and test vehicles
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Prototype and validation vehicles
The focus is on technically and economically optimized system solutions that can be efficiently integrated into existing or new vehicle platforms.
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Legal, technical, and vehicle-specific requirements should be considered during the development phase. This helps avoid later adjustments and allows for efficient preparation of approval processes.
Depending on the project scope, this includes, among other things:
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UN/ECE regulations
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EU type approvals
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Road Traffic Licensing Regulations (StVZO) requirements
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EMC and electrical safety requirements
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Axle load, center of gravity and weight specifications
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Bodybuilder guidelines
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OEM specifications
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Requirements for lighting, signaling systems and vehicle bodies
Topics such as:
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High-voltage integration
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thermal protection
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Add-on parts & interfaces
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Structural and long-term durability
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Packaging & Installation Space
are integrated into the development process at an early stage.
VELA takes these requirements into account in early development phases and develops integration- and certification-ready vehicle solutions with high technical feasibility and reduced project risk.
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Lightweight materials are used wherever weight needs to be reduced, moving masses decreased, or multiple functions combined in a single component. However, the decisive factor is not the material itself, but the most economically viable overall solution.
Lightweight construction offers advantages, for example, in:
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moving machine components
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Robotics and Automation
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highly dynamic assemblies
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ergonomic handling systems
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mobile devices and systems
VELA develops material-optimized components made of metal, plastic and fiber composites , optimally coordinating material, design and manufacturing.
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The choice of material affects not only weight and stability, but also manufacturing costs, tooling requirements, and economic efficiency. Therefore, material and manufacturing process should always be considered together.
The following factors, among others, play a role in the selection process:
planned quantities
mechanical loads
Component geometry
Surface requirements
Tooling costs
Assembly and system costs
Serial production capability
VELA provides support as early as the concept phase in selecting suitable materials and manufacturing processes and develops economical solutions for prototypes, small series and series products.
Successful industrialization begins during the development phase. By considering manufacturing processes, assembly, quality assurance, and the supply chain early on, later changes can be avoided and products can be brought into mass production more quickly.
A development process suitable for series production takes into account, among other things:
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Manufacturing strategy
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Tool concepts
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Material selection
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Assembly processes
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Quality assurance
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Scalability
VELA supports projects v
from the initial concept idea through prototypes and small series to industrialization and mass production.
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Medical device components often have to meet the highest demands in terms of precision, surface quality, material selection, and reproducible manufacturing processes. Regulatory requirements and subsequent manufacturability should also be considered during the development phase.
Depending on the application, the following aspects, among others, play a role:
Precision and dimensional accuracy
Surface and material requirements
Cleaning ability
documented development processes
reproducible manufacturing quality
Integration into existing systems
VELA develops customer-specific components, housings and assemblies for medical technology applications , taking into account project-specific quality and manufacturing requirements.
The choice of the appropriate manufacturing process significantly influences tooling costs, component costs, and the economic viability of a project. As early as the concept phase, it should be determined which process offers the best solution in terms of quantity, geometry, and technical requirements.
Key selection criteria include:
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Quantities
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Tooling costs
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Level of integration
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Weight & structural load
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Surface requirements
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UV and temperature resistance
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Repairability
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Assembly and system costs
Typical manufacturing processes compared
Proceedings
GRP hand laminate
RTM / Infusion
Deep drawing
SMC / Pressing process
Carbon composite
Typical quantities
1–50 pieces
50–500 pieces
100–5,000 pieces
>1,000 pieces
Prototype / Small series
Tooling costs
small amountmedium
medium
high
medium-high
VELA supports customers as early as the concept phase in selecting the most economical manufacturing process and develops plastic, thermoformed, composite and fiber composite components – from prototype to series production.
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