Development "We Combine Materials, Manufacturing, And Digital Validation"

Related Vendors

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Chassis and body bear higher loads in e-vehicles. What does this mean for development and production? Ulf Sudowe, Head of Chassis Development at Gestamp, explains it.

Mr. Sudowe, what are the biggest challenges currently facing Gestamp, and how is the company responding to them?

The increasingly strict environmental regulations and growing electrification make lightweight construction a strategic priority for us in vehicle development. Other key development criteria include the efficient use of resources and the reduction of CO₂ emissions—both during production and throughout the vehicle's lifespan. Therefore, close collaboration with automotive manufacturers is essential, supported by a coordinated innovation network.

In parallel, we are undergoing an organizational transformation. We are breaking down traditional communication barriers between the Body-in-White and Chassis departments. The goal is a dynamic matrix structure with increased cross-departmental collaboration and knowledge exchange. This enables us to merge technologies and product knowledge, unlocking new potential for comprehensive innovations at the module and system levels.

Some of your current products focus on lightweight construction in cars. The topic seemed less relevant with the emergence of electric cars. Why was that—and what development do you see now?

Originally, the lightweight construction concept seemed less significant for electric vehicles, as the industry's focus shifted to batteries, range, and charging infrastructure. Additionally, the consensus appeared to be that without a combustion engine emitting exhaust gases, lightweight construction would take a back seat. However, it quickly became clear that lightweight construction is even more important for electric vehicles than for combustion engine models. Vehicles are significantly heavier with batteries, and every additional kilogram reduces range and increases energy consumption. From my perspective, chassis and body components must therefore become lighter.

The Multipath Platform Concept simplifies production and reduces manufacturing costs. To what extent—and can the approach be expanded to other product areas?

"The 'Multipath Platform Concept' by Gestamp is an innovative and strategic milestone in the modular design of chassis components. At its core, it is based on a standardized, highly adaptable base frame that supports various drive types—from combustion engines to plug-in hybrids and battery-electric vehicles. Automotive manufacturers benefit from several advantages, including streamlined development processes, reduced tool complexity, faster production ramps, lower unit costs, and greater design flexibility."

How extensively do you use machine learning and artificial intelligence in development and production—and what specific advantages do you see?

We integrate machine learning and artificial intelligence into product development and manufacturing. They enable smarter, faster, and more efficient development and production processes. In component development, we optimize development and decision-making processes throughout the product lifecycle using machine learning and artificial intelligence. With the help of predictive algorithms and data-driven design tools, we test numerous variants, material combinations, and structural configurations already during the concept and design phase. This allows us to find optimal solutions faster with significantly fewer iterative development cycles.

In manufacturing, intelligent systems monitor process variables, predict maintenance needs, and optimize quality control in real time. This creates a seamless and continuous exchange between production and development—insights from manufacturing flow directly into future development projects.

Where is the development of common parts in chassis heading— what are automotive customers requesting in their predevelopment?

The automotive industry is undergoing a profound transformation—driven by electrification, autonomous technologies, and global platform strategies. The development of chassis components as standard parts is becoming more important—greater modularity, higher flexibility, and increased cost efficiency are coming into focus. This is not a short-term trend but a strategic and well-founded evolution of concepts for vehicle development and manufacturing. More and more OEMs are adopting modular design philosophies, where chassis systems are divided into shared modules. The advantages include fewer individual parts, lower tooling investments, and shorter development cycles.

At the same time, customer priorities are shifting. While lightweight construction remains a focus—particularly for greater range and efficiency—the integration of components and shared parts is increasingly taking center stage. This reflects a shift in thinking: production and process efficiency, supply chain robustness, and platform versatility are just as critical to competitiveness as the last kilogram saved. As modular chassis strategies mature, they will play a key role—enabling flexible vehicle architectures that can quickly adapt to changing market demands, from urban electric vehicles to autonomous delivery platforms.

Are the requirements for materials for chassis components still changing significantly—or is the current portfolio of aluminum and steel essentially fully developed?

Currently, some automakers and suppliers are testing innovative materials in body and chassis applications—primarily due to their extreme lightweight potential. Nevertheless, a clear trend is emerging in the industry for the next five years. The focus will continue to be on established materials such as steel and aluminum. Their proven recyclability and cost-effectiveness keep them as the preferred choice. New production methods in electric arc furnaces or via DRI processes will significantly reduce the CO₂ footprint of steel production. The material still offers an optimal balance of weight, strength, and cost. Advances in grades of advanced high-strength steels and ultra-high-strength steels enable thinner and more complex components—the foundation for innovative crash management concepts and a closer integration of chassis and BIW development.

What new materials will we see in chassis over the next five years?

Corrosion protection remains essential, especially for electric vehicles; coating technologies such as next-generation galvanized steels and our Corprosol, a special coating lacquer for chassis components, are used here. Carbon fibers and polymer composites will, for now, remain niche materials for high-performance and luxury vehicles. However, we are evaluating hybrid material systems for cost-effectiveness and scalability.

Research into new materials remains important—however, the pragmatic approach involves optimizing conventional alloys through modern processes, shaping, and surface technologies. This way, we combine sustainability, safety, and performance in chassis development.

What is Gestamp doing for sustainable production and a European circular economy?

We are decarbonizing mobility and industry by designing, developing, and manufacturing sustainable products with environmentally friendly industrial technologies and processes. We are transforming our industrial processes with a focus on electrification, energy efficiency, and renewable energy sources. In 2024, we established principles for efficient energy management across all our global locations.

With "Gescrap," we have also implemented a complete traceability system for the lifecycle of scrap. It ensures that we efficiently reuse this scarce secondary raw material. The goal is to promote the circular economy toward the net-zero vehicle. We apply the circular economy model comprehensively to high-quality scrap across all our processes and in our relationships with stakeholders. By 2050, we aim to operate climate-neutrally.

How do you attract skilled workers and ensure their retention in the long term?

We operate our own university, where we train our colleagues and young talents for future tasks. In addition, we educate people in the core technologies of the company at the Gestamp Technology Institute. The automotive industry requires very specific skills from both an industrial and digital perspective. The shortage of STEM talents and STEM-related professions in schools, high schools, and universities makes it challenging to integrate digital talents into the industry. We need to make science and industry more attractive.

What new products will Gestamp introduce in the next three years?

In the coming years, our focus will clearly be on electrification. Additionally, we are developing lightweight technologies and aim to improve vehicle safety. We are launching a range of new chassis products in which we combine advanced materials, innovative manufacturing techniques, and digital validation tools. With this, we aim to measurably improve three areas: crash safety, vehicle weight, and production efficiency—all without compromising on cost or the scalability of the architecture.

Machine Authentication

Machine Operator Authentication - Why knowing "who" matters