The course covers the principles for lightweight design as well as methods for analyzing the load carrying and failure behavior of lightweight structures.

Teams of 2 to 3 students have to design, size, and manufacture a lightweight structre complying with given specifications. An aircraft wing spar prototype as well as later a second improved spar will be tested and assessed regarding to design and to structural mechanical criteria.

The course focuses on manufacturing of fiber reinforced polymer (FRP) lightweight structures. It covers basic requirements, fiber & matrix materials, manufacturing process modelling & implementation, joining technologies, quality control & testing and economic & ecological aspects. The course combines lectures (2 h/week) with 7 hands-on lab exercises (3 h) and 5 written exercises (1 h).