Simulated crash for the...

Pushing the boundaries – the technological capacity of the Audi Q7 is impressive.

Audi worked with simulation experts, TECOSIM, to develop the Q7’s underlying crash-optimised car body platform.

The Challenge

With the conception of the Audi Q7, there was scope for many comfort and drive variants.

Audi has developed long and short versions of the vehicle body platform for petrol, diesel and hybrid engines.

During a crash, each variation had to perform well, irrespective of platform weight.

In addition to occupant safety, an accident-safe design of safety-relevant high-voltage components had to be developed. This design needed to eliminate any danger to occupants whilst causing no damage to hybrid batteries.

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Project Description Info Box

  • Development of a crash-optimised platform
  • Simulation of all international crash load cases
  • Calculation and simulation of structural rigidity
  • FE calculations to select material quality grades and thickness widths


The Audi Group is one of the most successful car and motorcycle manufacturers in the world.

In 2016, the Audi Group produced approximately 1.87 million Audi-brand cars, 3,457 Lamborghini sports cars and 55,451 Ducati motorcycles.

In this same year, they achieved an EBIT of 3.1 billion euros from a turnover of 59.3 billion.

Around 88,000 people are employed by Audi Group worldwide (over 60,000 of which work in Germany.)

The group is working on sustainable products and technologies for future transport.

For further information on Audi:


  • Calculation and protection of the vehicle body platform
  • Successful front impact in the small overlap test
  • Calculation for rear impact load and car body optimisation

Weight optimisation with the aid of finite element (FE) calculations

TECOSIM Company Profile

A team of over 460 computer-aided engineering (CAE) specialists positions TECOSIM as the go-to development process partner. With branches in the UK, Japan, India, Germany and Romania we deliver unbeatable solutions that fully satisfy your requirements.

The Solution

TECOSIM simulated different crash load cases. In addition to this, the team assisted Audi in the creation of a crash-optimised car body platform.

Expert engineers used finite element (FE) calculations, mapping specific stress load behaviours to technologies and various grade materials.

  • Development of a laminated glass simulation method which far exceeds previous standards
  • High prediction accuracy regarding the risks of injury for head impacts on a windscreen
  • Simulation results can be incorporated into new car designs immediately
  • Recommendations for improvements to structural designs for windscreens and panoramic windscreens.
  • A research project funded by the German Federal Ministry of Economics and Technology (BMWi).

TECOSIM Services

Crash scenario simulations

TECOSIM’s contribution ensured that the newly developed platform was safe for all crash load cases. The engineers focused on the small overlap crash test requirements, which the vehicle’s predecessor was not able to meet.

In addition to this, simulations and load value calculations were carried out for the hybrid battery layout in various rear crash scenarios.

Vehicle body crash optimisation for hybrid drives

During crash optimisation, TECOSIM had to guarantee structural rigidity. Additionally, vehicle weight and cost needed to be kept within strict limits.

The CAE experts took manufacturing and production conditions into account whilst developing components for the different load paths.

Weight reduction calculations 

A primary objective was to reduce the weight of the vehicle body significantly. TECOSIM’s FE calculations were utilized, optimising different materials (aluminium, normal steel and high-strength steel) in relation to the stress load and body structure layout. The desired result was achieved.

Benefit to the client

The result of this challenging task was the production of a comparatively lightweight vehicle body. Budget requirements were met whilst the solution complied with all safety requirements.

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