Abstract: A process for the manufacture of a large area sheet metal part, in particular a body component for a vehicle, from a flat blank, provides that one sided pressurization with an active medium in a forming tool gives the flat blank a prestretched preform, and that then the preform, removed from the forming tool, is formed into the final shape in a separate deep drawing tool.

Abstract: A vehicle side door or hatchback structure incorporates at least one hydroformed component. In one configuration, a window frame, a door frame and a reinforcement member are press-fit together by pressurized fluid during a hydroforming process to join the frames and the reinforcement member together. In another configuration, a vehicle hatchback frame subassembly includes a one-piece hydroformed window frame with a central portion disposed between opposing end portions. Inner and outer panels are attached to each other and secured to the opposing end portions of the window frame. In yet another configuration, a vehicle door and window frame subassembly includes a hydroformed one-piece first door frame, a roll formed second door frame and a reinforcement member secured to the tubular one-piece first door frame. An outer front panel is attached to the reinforcement member by at least one mirror bracket.

Abstract: Method and system for designing and producing a lightweight automobile or vehicle body. Structural performance targets are selected, a beam model analysis is conducted, and a body-in-white design is developed. A shell model is created and analyzed and material gauges and manufacturing processes for the body components are selected. A structural analysis is conducted to determine whether the shell model meets the selected structural performance targets. A crash model is created, analyzed, and modified until satisfactory crash requirements are met. A final structural analysis is conducted to determine whether the shell model meets the selected structural performance targets.