CASE and Weight Reduction Development of Automobile

Importance of the Topic

Driven by the imperative to achieve carbon neutrality and the rapid evolution of automotive systems under the CASE framework (Connected, Autonomous, Shared & Services, Electrification), the industry must integrate advanced functionalities while minimizing vehicle weight to enhance efficiency, range, and safety. Analytical and testing methods are critical enablers for material innovation, component validation, and system reliability throughout this transformation.

Objectives and Study Overview

This review presents a collection of evaluation applications and Shimadzu analytical, testing, and measurement instruments designed to address CASE mobility challenges and weight reduction goals. It covers 5G communication modules, LiDAR and sensor materials, in-vehicle air quality, electric motor and battery components, electronic control units, and advanced lightweight structures such as composites, sheet metals, and additively manufactured parts.

Methodology and Instrumentation

• High-frequency PCB and resin assessment: electron probe microanalysis (EPMA), FTIR, thermogravimetric analysis (TGA), microfocus X-ray CT.
• LiDAR optical property testing: UV-VIS-NIR spectrophotometry.
• Driver cognitive load monitoring: functional near-infrared spectroscopy (fNIRS).
• Photocatalyst charge mapping: scanning probe microscopy (SPM) under illumination.
• VOC/SVOC profiling in interiors: thermal desorption gas chromatography-mass spectrometry (TD-GC-MS).
• Radial forging impact on motor shafts: AGX-V2 precision universal tester.
• Battery material imaging and analysis: X-ray CT, scanning probe microscope (AFM), differential scanning calorimetry (DSC), FTIR, evolved gas analysis.
• ECU and circuit board inspection: microfocus X-ray CT, X-ray fluoroscopy.
• Composite and sheet metal validation: CT imaging, high-speed bending/compression testers, digital image correlation (DIC).
• Additive manufacturing defect evaluation: CT, ultrasonic fatigue testing.
• Plastic molding parameter studies: tensile testers, micro-hardness testers, FTIR, UV-Vis, DSC.

Main Results and Discussion

• Connected: Identification of low-loss resin alternatives for 5G PCBs; CT detection of internal defects in smartphone boards.
• Autonomous: Spectrophotometric validation of LiDAR filter performance; fNIRS-based measurement of driver brain activation in simulated scenarios.
• Shared & Services: Visualization of photocatalyst surface potential changes; quantitative analysis of interior VOC/SVOC emissions under automotive standards.
• Electrification (motors): Mapping of tensile strength and elongation across forged shaft cross-sections to guide hollow component production.
• Electrification (batteries): In-situ AFM and CT for electrode architecture; DSC and evolved gas analysis revealing degradation mechanisms.
• Inverters: Non-destructive X-ray CT and EPMA exposing solder joint defects and intermetallic layer distributions.
• Composites: Multiscale V&V improved simulation accuracy using CT-based microstructure data; high-strain-rate testing informed impact resilience models.
• Sheet metal forming: Bauschinger effect measurements enhanced springback predictions; high-speed tensile tests characterized strain-rate sensitivity.
• Dissimilar material joining: Ultrasonic imaging and CT visualized bond integrity; EPMA detailed interfacial chemistry affecting joint strength.
• Shape optimization: CT correlation of pore morphology in 3D-printed alloys with ultrasonic fatigue life data.
• Plastic molding: Blend ratio, mixing and annealing studies linked processing conditions to mechanical, thermal, and optical performance.

Benefits and Practical Applications

By leveraging a comprehensive suite of analytical platforms, R&D teams can optimize material selection, refine processing parameters, and verify component durability. These capabilities support the development of robust 5G modules, accurate autonomous sensors, odor-free shared interiors, high-efficiency electric drivetrains, and lightweight structures that meet stringent performance requirements.

Future Trends and Applications

• Increased use of in-situ and operando measurements for real-time monitoring of manufacturing and degradation.
• AI-powered image analysis to expedite defect detection and predictive maintenance workflows.
• Integration of multimodal datasets to build comprehensive digital twins in automotive engineering.
• Expansion of non-destructive evaluation techniques to novel composites and additive manufacturing materials.
• Development of portable analytical instruments for on-site quality control throughout supply chains.

Conclusion

The convergence of CASE mobility demands and weight reduction imperatives requires precise, multifaceted analytical and testing methodologies. Shimadzu’s diverse instrument portfolio delivers critical insights into material behavior and component performance, empowering the automotive industry to design safer, more efficient, and lighter vehicles for the next century.