Research | MobiXL: The Synergy of Topological Optimization and Modular Production - Exploit Innovation Potential Now! — Photon

With MobiXL, Photon Laser Manufacturing is working on an innovative manufacturing method that has the potential to significantly change the production of large components for rail vehicles, aviation and shipbuilding.

By combining bionic optimization and modular construction, a new approach for sustainable, economical and flexible vehicle production is being launched. In the face of rising energy prices, stricter CO2 regulations and growing demands for resource efficiency, MobiXL offers promising approaches for manufacturers and operators of mobility solutions.

Maximum efficiency through innovative production

At the heart of this new technology is a process in which highly complex, topology-optimized stiffening structures are converted into standardized, serially manufactured modules. The non-linear, weight-optimized stiffening structures are then built from these modules. While additive processes are often limited by long production times and high costs, MobiXL can combine the advantages of classic series production with the degrees of freedom of topologically optimized designs, leading to more efficient and flexible production, which will enable the possibilities of economical production of weight-optimized structures.

One focus is on efficient and proven joining technology: the modules are to be joined using low-distortion laser welding. The aim is to achieve maximum structural stability and enable a reduction in production time. In addition, the process chain is to be fully digitalized, which should contribute to consistent quality assurance, minimize error rates and ensure reproducible results – a decisive advantage for manufacturers and operators with high safety and efficiency requirements.

Economic potential for manufacturers and operators

MobiXL will enable significant savings along the entire value chain. The targeted weight saving of up to 20% compared to existing laser-welded stiffening structures not only allows the use of materials to be reduced, but also cuts energy consumption over the entire service life of a vehicle. This leads to lower operating costs, reduced emissions and a longer service life for the components used.

Another advantage lies in the flexibility that can be achieved in production. MobiXL will make it possible to efficiently implement individual adaptations to different vehicle types. In future, manufacturers will be able to react more quickly to market requirements and realize innovative designs without disproportionately increasing production costs.

Sustainability as a strategic competitive advantage

In addition to the economic prospects, MobiXL will also make an important contribution to sustainable mobility. By reducing the use of materials, making production processes more efficient and reducing energy consumption over the entire life cycle of a vehicle, this process will help to minimize the ecological footprint. These approaches are of particular interest to companies that have set themselves ambitious sustainability targets and want to actively improve their carbon footprint.

MobiXL – future prospects for vehicle construction

Initial results on the potential of MobiXL technology have been demonstrated by testing industry-specific demonstrators for rail vehicle and shipbuilding. The project was funded by the Federal Ministry for Economic Affairs and Climate Protection as part of the Lightweight Construction Technology Transfer Programme (TTP LB) and shows how modularization, digitalization and automation can lead to more efficient, economical and sustainable production processes in the long term.

MobiXL offers manufacturers, operators and political decision-makers new approaches to the challenges of modern mobility. Anyone working on forward-looking concepts for economical and sustainable lightweight construction today will soon be able to benefit from this new technology.