Structural analysis of lightweight components for heavy vehicles: a project of integration between polymers and metals

Abstract The replacement of metallic materials with polymers in vehicles is a growing trend in the automotive industry, driven by the need to increase load capacity and improve overall vehicle performance. Through structural analyses, this study evaluates the technical and economic feasibility of applying plastic parts in place of metallic parts. This work proposes the study of the development of automotive solutions aimed at reducing weight and fuel consumption by adapting metallic components to plastic components (using as a reference the development of a truck bumper made of plastic with an internal aluminum structure). In addition, the work addresses compliance with current Brazilian legislation, including CONTRAN standards, ensuring that the proposal is in accordance with safety and performance requirements. The study concludes that the use of polymers to replace metallic parts in automotive components can bring significant benefits (energy efficiency, for example) as long as legal and technical limitations are respected.