Collaborative Optimization of Lightweighting and Safety: A Review of the Research on Vehicle Structural Design

Sicheng Zhao

doi:10.54254/2755-2721/2025.LD30015

Applied and Computational EngineeringOpen access

Collaborative Optimization of Lightweighting and Safety: A Review of the Research on Vehicle Structural Design

Research Article

Open Access

Collaborative Optimization of Lightweighting and Safety: A Review of the Research on Vehicle Structural Design

Sicheng Zhao ^1*

¹ Shanghai Experimental Foreign Language School, Shanghai, China, 200093

^*Corresponding author: 18621707245@163.com

Published on 26 November 2025

ACE Vol.210

ISSN (Print): 2755-273X

ISSN (Online): 2755-2721

ISBN (Print): 978-1-80590-567-7

ISBN (Online): 978-1-80590-568-4

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Abstract

In the context of the rapid development of electrification and intelligentization in the global automotive industry, vehicle structure design is undergoing a paradigm shift. Modern automotive structures face the increasing pressure of safety requirements and the dual pressures of improving energy efficiency and reducing emissions while extending driving range. This paper systematically analyzes the main characteristics of modern automotive structures and focuses on the technical route and key challenges of lightweighting and safety integrated optimization. The evolution of methodologies and the essential value of vehicle structural optimization are presented. Current optimization strategies mainly involve topology optimization, dimensional and shape optimization, and material selection optimization. The relevant technologies for optimization include lightweight design, crashworthiness enhancement, and manufacturing constraint consideration optimization. Main challenges include high computational cost and efficiency, multi-objective trade-offs, few experimental verifications, and difficulties in standardization and industrialization. This paper emphasizes the interdisciplinary collaboration between different disciplines.

Keywords:

Lightweighting, Vehicle Structural Optimisation, Crashworthiness, Driving Safety, Topology Optimisation

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References

[1]. Li, X. (2025). Current status and outlook of lightweighting technologies for new energy vehicles. Automotive Digest, (3), 17-23. doi: 10.19822/j.cnki.1671-6329.20230273.

[2]. Shan, K. Z., Wang Kedong, Liu Chao, Hu Xuefang & Mo Yanbin. (2023). Lightweight design of automotive engine mounts based on topology optimisation. Automotive Practical Technology, 48(23), 68–73. doi: 10.16638/j.cnki.1671-7988.2023.023.013.

[3]. Jiang, Q., Wu, J. & Shi, G. (2024). Optimisation design of electric vehicle sill beam cross-section based on the movable deformation component method. Shanghai Automobile, (12), 19-26.

[4]. Zhou, W. L. (2025). Exploring optimised design and analysis of automotive body structures using lightweight materials. Times Automotive, (7) : 120-122.

[5]. Yan, L. & Xu, H. 2025. Lightweight composite materials in automotive engineering: State-of-the-art and future trends. Alexandria Engineering Journal, 118, pp. 1-10.

[6]. Shi, P., Shan, Z., Zhu, H., Hai, B., Wang, L., & Lu, F. (2025). Integrated design technology for new energy vehicle power battery systems. Chinese Journal of Mechanical Engineering, 36(7), 1611–1623.

[7]. Lei, Z. B. & Yi, X. J. (2016). Multi-objective topology optimisation for collision safety and NVH in electric vehicles. Journal of Highway and Transportation Engineering, 29(5), 144-150.

[8]. S. Almeaibed, S. Al-Rubaye, A. Tsourdos and N. P. Avdelidis, 'Digital Twin Analysis to Promote Safety and Security in Autonomous Vehicles, ’ in IEEE Communications Standards Magazine, vol. 5, no. 1, pp. 40-46, March 2021, doi: 10.1109/MCOMSTD.011.2100004.

References

[1]. Li, X. (2025). Current status and outlook of lightweighting technologies for new energy vehicles. Automotive Digest, (3), 17-23. doi: 10.19822/j.cnki.1671-6329.20230273.

[3]. Jiang, Q., Wu, J. & Shi, G. (2024). Optimisation design of electric vehicle sill beam cross-section based on the movable deformation component method. Shanghai Automobile, (12), 19-26.

[4]. Zhou, W. L. (2025). Exploring optimised design and analysis of automotive body structures using lightweight materials. Times Automotive, (7) : 120-122.

[5]. Yan, L. & Xu, H. 2025. Lightweight composite materials in automotive engineering: State-of-the-art and future trends. Alexandria Engineering Journal, 118, pp. 1-10.

[7]. Lei, Z. B. & Yi, X. J. (2016). Multi-objective topology optimisation for collision safety and NVH in electric vehicles. Journal of Highway and Transportation Engineering, 29(5), 144-150.

Cite this article

Zhao,S. (2025). Collaborative Optimization of Lightweighting and Safety: A Review of the Research on Vehicle Structural Design. Applied and Computational Engineering,210,63-69.

Data availability

The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

About volume

Volume title: Proceedings of CONF-MLA 2025 Symposium: Intelligent Systems and Automation: AI Models, IoT, and Robotic Algorithms

ISBN: 978-1-80590-567-7(Print) / 978-1-80590-568-4(Online)

Editor: Hisham AbouGrad

Conference website: https://www.confmla.org/london.html

Conference date: 12 November 2025

Series: Applied and Computational Engineering

Volume number: Vol.210

ISSN: 2755-2721(Print) / 2755-273X(Online)

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