Parametric modeling was used to build several models of an automotive front structure concept that utilizes carbon fiber composite materials and the corresponding molding processes. An ultra-lightweight aluminum body front Structure was redesigned to include an all-composite front structure. Two alternative concepts were studied which represent the structure as a bonded assembly of shells. Closed sections result from two pieces an inner and outer. Parametric modeling was found to be a useful tool for building and modifying models to use in optimization concept studies.

Such models can be built quickly and both the sketch dimensionsand location dimensions are particularly useful formaking the adjustments necessary to fit the various bodypieces together. The parametric models then must be joined Together as one geometric solid model in order to obtain asurface mesh. Structural optimization input data can then beseamlessly and quickly created from the parametric-modelbasedfinite element model to begin the tradeoff studies. This integrated process in which parametric modeling was coupled With structural optimization was used to carry out designstudies on the lightweight body front structure. Several carbonfiber material combinations were studied to determinemass reduction potential of certain types of carbon fiberproducts considered to be lower cost than typical carbonfiber materials used in the past. Structural optimization wasused to compare several composite constructions for thedesign of the bonded front structure. Eight cases were studiedusing various materials and composite lay-ups.