Semi-automatic design of crash management systems
ALU-CAR and FOXBYTE are taking the engineering process for crash management systems to a new level
A short jolt and a muffled noise — a moment many drivers unfortunately know all too well. It happens when you brake too late while parking, hit an inconspicuous post, or simply have too little space. These everyday collisions may seem harmless, but they place high demands on the safety systems of modern vehicles.
A good crash management system (CMS), often referred to as a ‘bumper’, must function flawlessly in these situations. It protects both the vehicle structure and the driver's nerves.
What looks simple from the outside is actually a highly developed, finely balanced system. At ALU-CAR, we design these systems with great experience and precision. Our efficient and fast design process sets new standards with its digitalization. This ensures the optimal function of the CMS.
Efficient engineering starts with details - and ends with an advantage
Developing a CMS involves much more than designing a component. It involves the optimal use of the available installation space between the body structure and vehicle design. It involves defined connection points, clear load paths, and standardized testing conditions.
At the end of the day, it's all about one thing.
Making the right decision from a wide range of options as efficiently as possible.
This is often where the bottleneck lies.
The performance of the CMS is influenced by countless design decisions, from the positioning of connections (weld seam, spotwelds, glue) to the geometric design of the energy absorbers. Each variant must be designed, simulated, and evaluated. Time is of the essence.
More variants. More depth. More clarity.
With the CMS workflow from ALU-CAR and FOXBYTE
In collaboration with FOXBYTE, the csi Group's business unit specializing in software solutions, we have developed a semi-automated engineering workflow that addresses this challenge.
Based on a modular automation concept, it provides support exactly where it is needed.
- Recurring steps, such as meshing, modeling, connection technology, and evaluation, are automated.
- Experts at ALU-CAR retain control at all times and can evaluate the results more precisely.
- The CMS variants are created faster, more broadly, and more structurally than before.
The advantage for our customers:
In the same development time, we can evaluate more variants — more thoroughly, specifically, and with measurable added value. Because every day counts.
We think from an engineering perspective.
This approach sets itself apart from classic automation solutions. Rather than relying on colorful interfaces or rigid tools, our experts develop lean, adaptable solutions based on genuine CAx expertise. We use Python scripts to seamlessly integrate top-tier tools like CATIA, ANSA, Animator, and Meta, eliminating unnecessary complexity and detours.
The process remains in the hands of those who understand it.
Understand and optimize
Our strength lies in our combination of engineering expertise and digital implementation know-how.
ALU-CAR brings speed and system understanding to CMS design.
FOXBYTE provides the digital infrastructure and automation logic that make processes lean and scalable.
Together, we create solutions that are technically impressive and offer tangible benefits in everyday development.
Digitalization that creates real added value.
Our claim is clear:
We design efficient engineering processes — directly increasing added value for our customers.
Whether they want to compare variants, speed up projects, or reduce process costs, we can help. With us, our customers gain the clarity, speed, and depth that modern CMS development requires.
And if it’s just a little tap? That's when the value of our head start becomes clear.
