Car Body Development for the next generation of vehicles
Comprehensive, efficient, and simulation-driven Car Body Development
Modern body engineering requires a holistic approach to structure, materials, and function. Our engineers develop vehicle body structures from the earliest stages of vehicle architecture and define simulation-driven load path concepts that ensure compliance with applicable regulations - all the way through to detailed production development. Upon request, we can also handle the production of ready-to-use prototypes.
Our expertise in the areas of system development and design, NVH and structural integrity, and crash and passive safety all work together seamlessly.
Even in the early stages of a project, we take into account the optimization of manufacturing costs, the carbon footprint, and opportunities for lightweight construction. Safety is always our top priority. Our experienced passive safety team ensures that every body development project results in a holistically safe vehicle concept.
In the context of autonomous and electric vehicle architectures, we are already developing body structures for new vehicle layouts. This gives rise to new packaging requirements, altered load paths, and additional integration needs - for example, for sensors and battery systems. Thanks to the close integration of our disciplines, we are able to implement even complex requirements efficiently and effectively.
Together, we are shaping the future of the automobile.
Engineering across all mobility segments
We support established OEMs, agile startups, and specialized niche providers with scalable, technologically advanced body solutions - from hypercars to autonomous people movers. We cover all relevant vehicle architectures - from battery-electric and conventional vehicles to flexible platform concepts.
Automotive (OEM)
We have many years of experience in series production development for established OEMs and take on responsibility for the body design of current production vehicles. Our services also include comprehensive simulation activities, particularly in the areas of structural strength, NVH, and crash testing. We are recognized by many OEMs as a reliable and established development partner, particularly in simulation and passive safety. In addition, we carry out exclusive international hypercar projects for well-known manufacturers - whether as monocoque or multimaterial designs - and apply our production experience specifically to highly specialized applications.
New Mobility & Automotive Start-ups
We support established OEMs in the development of current production vehicles and assume responsibility for body engineering deliverables across the development process. Our capabilities include comprehensive CAE activities covering structural strength, NVH, crashworthiness, and passive safety. In particular, our simulation and safety experts are firmly integrated into the development processes of many OEMs. In parallel, we realize exclusive hypercar projects for internationally recognized manufacturers, developing advanced monocoque and multi-material structures while leveraging proven series-development methodologies for highly specialized vehicle programs.
Commercial Vehicles
We develop body structures for commercial vehicles across a broad spectrum of applications, including vans, truck cabs, and specialized vehicle concepts. Our scope ranges from the optimization of existing products to complete new vehicle developments for emerging manufacturers. Our services cover structural development, body engineering, detailed design, and CAE-based validation, particularly in the areas of NVH, durability, and crashworthiness. Leveraging established passenger car development methodologies, we deliver efficient and robust solutions tailored to the specific requirements and operating conditions of commercial vehicles.
Luxury Vehicles
We have extensive experience in the development of luxury low-volume vehicles and engineer body structures for highly individual, premium vehicle programs with exceptional quality requirements. Our approach combines lean development processes with strong attention to detail and a pragmatic, hands-on engineering mindset. Clear ownership, short decision paths, and a high degree of autonomy enable efficient execution and consistent project delivery.
Tier 1 Support
We support Tier 1 suppliers in the development and engineering of components and systems for use in OEM vehicles. A particular focus lies on crash management systems, for which we provide comprehensive concept and development services. In addition, we develop body attachments and closure systems in various material configurations and support their development through to production readiness.
Holistic development – From defining goals to implementation
We integrate all relevant disciplines of Body Engineering into a unified engineering approach that spans the entire product development process.
At the heart of this approach is rigorous project management that efficiently coordinates processes, interfaces, and development targets. This ensures consistent development across all engineering disciplines and lays the foundation for high-quality, efficient, and on-time projects.
Our CAE development is consistently data-driven. Using machine learning and modern parameter optimization, we analyze extensive datasets, identify critical correlations early on, and derive optimal design decisions from them.
From the concept phase through detailed development, this results in efficiently optimized structures with precisely tuned performance in the areas of crash and NVH - while reducing development effort and ensuring a high degree of prediction accuracy.
Our services in Car Body Development
System Development & CAD Design
Our engineers combine a comprehensive understanding of vehicle systems with in-depth design expertise to develop vehicle bodies from the initial architectural concept through to series production. This results in function-, material-, and manufacturing-oriented solutions that equally balance technical requirements, manufacturability, and cost-effectiveness.
Aspects such as tolerance management, geometric and dimensional tolerances, and the joining concept development are incorporated into the development process at an early stage. Modern CAD methods and powerful development tools enable the rapid development of robust concepts even in the early project phases.
NVH & Strength
Using simulation-driven methods, we support our customers from the derivation of reliable development goals through to the design and optimization of body structures with regard to acoustics, vibration behavior, and durability.
We draw on decades of experience from German and international OEM projects. In addition, we possess comprehensive expertise in the design and evaluation of modern joining technologies, as well as extensive experience in CAE-based structural and parameter optimization.
Crash & Passive Safety
In the field of Crash & Passive Safety, we are a trusted development partner to leading German and international OEMs.
From target definition through load path concept development and validation, we support the engineering of safety-critical vehicle structures throughout the entire development process.
In doing so, we consider regulatory requirements, consumer safety ratings, and project-specific safety targets for occupant protection, pedestrian protection, and structural crash performance. Our experts develop robust solutions for a wide range of material concepts, combining decades of experience with state-of-the-art CAE methodologies.
Our in-house materials laboratory, extensive expertise in material card development and calibration, and the planning and supervision of physical crash testing activities through our certified crash test partner network further strengthen our development capabilities.
Full Vehicle & Package
Especially for startups and new vehicle programs, we take a holistic view of the vehicle as a whole from the earliest stages of development.
From vehicle geometry and vehicle architecture definition, through package investigations, to the definition of key vehicle requirements, we lay the foundation for a coherent overall concept. Throughout this process, we always keep a close eye on the interactions between the body, packaging, and functionality.
DFM & Assembly Sequences
Manufacturability and assembly feasibility are considered from the earliest stages of development. We evaluate manufacturing and joining concepts, take production and assembly requirements into account, and support in developing efficient manufacturing processes.
This results in body solutions that are not only technically robust but also economically viable.
Prototype Coordination
We support the transition from the digital development phase to physical implementation and, upon request, coordinate the build of complete vehicle prototypes through an established network within our corporate group and through established external partners.
For new vehicle manufacturers in particular, we take on overall responsibility for the entire process. The close involvement of our developers ensures seamless coordination between design, evaluation, and implementation.
In our own workshop, prototypes can also be analyzed, modified, or further developed into fully functional vehicles.
Car Body Development at Module Level
Materials
We have extensive experience in the development of body structures in steel, aluminum, and advanced multi-material designs - ranging from conventional stamped sheet-metal structures to aluminum structures with cast nodes and extrusions.
Composite structures have been among our core competencies for many years. From material-specific design to the development of highly integrated CFRP components and monocoques for exclusive vehicle projects, we combine deep materials expertise with comprehensive development and simulation expertise.
Body-in-white
The body-in-white is much more than a vehicle’s load-bearing structure. It has a significant impact on safety, driving dynamics, and efficiency.
In addition to production development, we are actively engaged in exploring the vehicle architectures of the future and investigating new body-in-white concepts - from sustainable steel structures and modern skateboard platforms to highly integrated bodies based on large structural castings.
Doors & Closures
Doors and closures are among the most technically challenging modules in a vehicle body.
We develop traditional side doors as well as hoods and tailgates, along with innovative access concepts for new vehicle architectures - ranging from sliding door systems to complex multi-hinged and double-wing doors.
In doing so, we take into account requirements regarding function, design, sealing concepts, misuse cases, pedestrian protection, and structural durability. Extensive kinematic analyses support the development of robust and user-friendly solutions.
Battery Integration & Cell-to-Body
As battery systems and vehicle structures become increasingly integrated, body engineering and high-voltage system development are becoming ever more closely interconnected.
Through close collaboration between our body and high-voltage system teams, we develop state-of-the-art cell-to-body concepts and create solutions that optimally combine structure, package, safety, and functionality.
You can find out more about our expertise in high-voltage battery systems here.