Lightweight Design worldwide

, Volume 11, Issue 3, pp 48–51 | Cite as

Lightweight coaches by integrated sandwich technology

  • Hanfried Hesselbarth
  • Simon Leutenegger
  • Markus Hartwig
Design Rail Vehicles

The Zurich University of Applied Sciences, together with Airex Composite Structures and Rapid Technic, used friction stir welding to join sandwich components with extruded profiles. The technology makes it possible to build lighter rail vehicles, comply with registration-relevant axle loads and minimize operating costs.

The Car Body as a Challenge

Manufacturers in the railway sector must pay attention to weight. A multitude of comfort and information equipement is required in today’s railway passenger cars. However, the allowed total weight per axle is still limited. In the near future, rail infrastructure usage fees will increasingly be based on the weight of trains. An innovative lightweight design is required. Sandwich element manufacturer Airex Composite Structures, the technology company Rapid Technic, and the School of Engineering of the Zurich University of Applied Sciences (ZHAW) launched a research project to develop the Integrated Sandwich Technology (ISTech) to meet the...



This research and developement project was funded by the Commision for Technology and Innovation (CTI) in Switzerland.


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    Leutenegger, S. et al.: Der Aluminium-Wagenkasten 4.1: Leichtbau durch integrierte FSW- Sandwiches. Conference Rad Schiene Tagung, Dresden (Germany), 2017Google Scholar

Copyright information

© Springer Fachmedien Wiesbaden 2018

Authors and Affiliations

  • Hanfried Hesselbarth
    • 1
  • Simon Leutenegger
    • 1
  • Markus Hartwig
    • 2
  1. 1.Zurich University of Applied Sciences (ZHAW)WinterthurSwitzerland
  2. 2.Airex Composite StructuresAltenrheinSwitzerland

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