Nowadays, the focus is on making lighter-weight, more fuel-efficient automobiles. Research into the manufacture of lightweight automobiles is driven by the need to reduce fuel consumption to preserve dwindling hydrocarbon resources without compromising other attributes such as safety, performance, recyclability and cost. Structural optimisation technique is employed to determine the optimal panel thickness. Finally, a multi-objective analysis is performed to identify the optimum door assembly. It is found that the optimal material and manufacturing process depend heavily on the production volume, the vehicle program and application.
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