How does Neway optimize structures to enhance lightweighting?

Neway applies an engineering-driven lightweighting strategy that combines structural design optimization, material selection, and manufacturing process integration to achieve weight reduction without compromising safety, stiffness, or durability. Across automotive, aerospace, and e-mobility applications, Neway adopts simulation-driven development, topology optimization, and high-precision manufacturing to push lightweighting capabilities while ensuring that crash safety, NVH stability, and fatigue life are fully maintained.

Simulation-Driven Structural Optimization

Lightweighting begins with digital engineering. Using topology optimization and FEA, Neway removes low-stress regions and reinforces load paths to create efficient structures. These optimized geometries are then validated through prototypes made via CNC machining prototyping or 3D printing prototyping. This ensures that designs are manufacturable and structurally robust before moving into production tooling.

Through advanced processes like aluminum die casting, precision casting, and metal injection molding, topology-optimized structures can incorporate ribs, hollow channels, lattice cores, and localized reinforcements in a single integrated part—minimizing weight while maximizing stiffness.

Material Strategy for Lightweighting

Neway matches structural requirements with the appropriate materials to deliver functional performance at the lowest weight possible. For primary load-bearing parts, high-strength aluminum alloys such as A356 and A380 are used with near-net-shape processes to reduce machining volume. For compact components requiring fatigue strength and dimensional precision, materials like MIM-4140 and MIM 17-4 PH via metal injection molding provide both durability and dimensional control.

In semi-structural housings, covers, and brackets, Neway leverages engineered polymers via injection molding to achieve 40–60% mass reduction compared to metal, using materials such as PC-PBT and nylon. These are reinforced locally at fastening points to ensure dimensional stability and vibration resistance.

Process Integration for Manufacturing Efficiency

Structural optimization is closely linked to manufacturability. Neway designs components around efficient processes such as precision casting, gravity casting, and sheet metal fabrication, ensuring that lightweight structures remain tolerant to real-world production variability.

Once the structure is optimized, surface treatment becomes essential for maintaining performance over time. Solutions such as anodizing, sandblasting, and heat treatment protect lightweight metals from corrosion and fatigue-driven failure, maintaining mechanical integrity throughout the service life.

Validation Through Prototyping and Testing

Before production, Neway builds prototypes through rapid molding prototyping to test impact resistance, stiffness, and fatigue performance. Physical testing is combined with simulation to ensure that lightweight designs still meet regulatory crash standards and customer-specific durability targets.

By integrating structural design, materials engineering, and manufacturing capability early in development, Neway consistently delivers lightweight, cost-effective, and production-ready components across multiple industries.