by Emily Newton
Lightweighting manufacturing efforts center on making products weigh as little as possible while ensuring they retain other desired characteristics, such as durability. Although this concept has a long history in the automotive industry, manufacturers of different products are exploring it, too. They realize there are many opportunities to use lightweighting in Industry 4.0, particularly when showing current or potential clients that a specific company is especially innovative and interested in pursuing pioneering ideas.
Advancing the future of aircraft
When an aircraft must fly for hours, it makes sense to evaluate lightweighting manufacturing techniques to optimize it. Succeeding could mean planes could make longer journeys before needing refueling because they will be more energy-efficient. Those working on this kind of lightweighting in Industry 4.0 also realize that lighter planes fit into aviation’s future, especially as more manufacturers and designers consider futuristic options to upgrade existing plane models.
One example comes from Airbus, which opened a specific facility in the United Kingdom to develop lightweight wings for newer versions of its popular A320 airliners. As of 2023, the center’s workers had built two of three planned full-size prototypes. However, rather than creating them to reflect an agreed-upon design, those involved have tested numerous potential technologies to see which ones get the company closest to its overarching goals.
This center also allows workers to investigate new manufacturing techniques, including those relying on automation. Company representatives hope to uncover new wing options that are lightweight, cost-efficient and scalable. Possibilities with all or most of those characteristics have the best chance of providing the viability a large company such as Airbus requires.
Enabling better portability through lightweighting manufacturing
Many lightweighting manufacturing projects involve participants catering to well-established or new needs. They realize that lighter, easy-to-handle products are obviously beneficial, especially when the designed item may be frequently moved rather than placed permanently in a location.
One example comes from South Korean steel manufacturer POSCO, which developed a new lightweight landing pad for buildings’ vertiports. This creation is more than 60% lighter than traditional counterparts, company representatives say.
User-friendliness is often a prominent factor influencing lightweighting in Industry 4.0. This vertiport landing pad is a case in point. Its modular design allows installation to occur in just eight hours, with disassembly requiring only two. Additionally, there is no need to pour concrete before using the landing pad, so it is easy to move between locations as required.
Making steel items lightweight enough to reposition frequently could also remove barriers t for people with physical disabilities. For example, portable steel ramps allow those who use wheelchairs or other mobility aids to access shops, event venues, workplaces and more.
Before producing portable items for specific customer groups, manufacturers and product development professionals should get feedback about which features would make items even more applicable to their needs. Does a portable ramp need a built-in handle? How many pieces should a modular landing pad have to support error-free assembly?
Manufacturing decision-makers should also consider which product factors are within their control. For example, the carbon emissions associated with foreign steel producers can be up to twice that of American companies offering the metal.
Although domestic steel can be more expensive than alternatives, sustainability-conscious leaders may prioritize the environmental benefits. It is also appealing that the United States has numerous metal and manufacturing standards that companies must uphold to operate within the country’s marketplace.
Making innovations more accessible
Lightweighting manufacturing operations often require specialty equipment that producers may not have in their facilities. However, thanks to forward-thinking efforts, today’s manufacturers may find creating and testing new, lightweight items easier than they envisioned. That is due to the wider availability of dedicated centers that enable experimentation with lightweight items.
A Scottish university has a facility for manufacturers interested in making such products, with a particular focus on how those products could support net-zero aims. One part of the center allows manufacturers to test different composite materials that are lighter than their conventional counterparts. Additionally, a project associated with this innovation lab involves making sustainable fibers from biomass, with participants hoping the results could eventually end up in cars or airplanes.
Fortunately, manufacturers can probably still find ways to innovate through lightweighting, even if there are no dedicated locations in their areas. One possibility is to work with a vendor that offers manufacturing-as-a-service plans. Then, customers can access various tailored resources without the high upfront costs usually required. Instead, they typically pay a flat fee for the specific services they want. Making changes to add or remove certain offerings is also usually possible, which helps producers remain flexible with limited commitments.
Another option is to use a 3D printer. Ongoing efforts have made them increasingly available in places such as schools and libraries. However, the industrial nature of the manufacturing industry means most interested parties would likely prefer to rent these machines by the hour, day or week. Many companies offer such arrangements, making it convenient to start creating lightweight prototypes.
Printers that allow working with multiple materials open additional possibilities, including one that can change filaments 50 times per second to support ultra-efficient results.
Catering to adventurers who want to travel light
Many people new to traveling overestimate what they need to pack, causing their friends to joke that it seems like they brought everything but their kitchen sinks. However, some individuals eventually realize it is far less of a hassle if they become light packers and take along only the essentials.
That mindset is crucial to people who aspire to backpack through multiple countries or hit the open road in their campers. Those excursions typically require careful planning, and many interested individuals appreciate when they can find lightweight items to accompany them on their travels. Airline weight limits are common, making it sensible to pack light items and put them into sleek suitcases.
Alternatively, every ounce counts when people plan to carry things on their backs for many miles. That is why some camping gear manufacturers offer products that serve dual purposes, such as soft air pumps that double as sleeping bag sacks.
However, some enthusiasts take an easier, albeit more expensive, route by saving up for campers. Lightweighting manufacturing marvels exist in that product category, too. One company makes its lightweight campers out of thermoplastic honeycomb material, with pieces ultrasonically welded to prevent leaks. That high-tech example highlights how the company moved forward with lightweighting in Industry 4.0 to solve the water ingress issues that many camper owners experience, even when following the recommended maintenance procedures.
Lightweighting in Industry 4.0 is here to stay
These examples show why many manufacturers feel it is necessary to prioritize lightweighting in their manufacturing goals. Many people appreciate lighter items, especially if they should last at least as long as their counterparts. Additionally, some individuals associate lightweight products with forward-thinking insights, allowing industry leaders to show they are ahead of the curve.
