Aluminum foam sandwich (AFS) is an innovative material for lightweight structures, consisting of an aluminum foam core surrounded by two face sheets of aluminum. The advantages of AFS are a low density combined with a high bending stiffness, good energy absorption properties, and high recyclability, meaning it can be used for many different applications. However, the number of realized series applications with AFS is low caused by a lack of design knowledge, as shown in various studies. In order to address this lack of design knowledge, a design guideline is to be developed. This paper focuses on the development of such a design guideline based on requirements and demands from the industry and presents a structure. In addition, the individual contents of the design guideline are explained in more detail in order to clarify how designers can be supported in the future when designing products with AFS, so that the full potential of this material can be realized. Finally, a survey in an industrial context evaluates the extent to which this design guideline is a useful form of support, in order to check whether its application can improve the design process with AFS.

Aluminum foam sandwich (AFS) is an innovative material for lightweight structures due to its various advantages (e.g. low specific mass). Today, many material properties (e.g. strength) are still not well researched, which is why AFS is not yet considered in current material selection processes. Therefore, AFS has rarely been used in the past and its application potential remains unused. This paper presents an approach toward an appropriate method for considering AFS in material selection processes to assist designers in evaluating whether the use of AFS in an application is profitable.

Aluminum foam sandwich (AFS) is an innovative material combination for designing lighter products and has many advantages such as a high bending stiffness at a low density and good energy absorption properties. Although the material is ready for series production, the number of industrial applications is low because of the high costs of the material, a lack of design knowledge and missing reference applications. This paper focuses on the aspect of missing reference applications and how to improve this situation in order to give designers an idea of where the material could be used profitably and to provide the basis for a selection method. Therefore, a systematic literature review is carried out to identify profitable applications with their respective advantages. As a main result, a set of motivators for the use of aluminum foam sandwich is developed, which will support the designer in evaluating the potential use of aluminum foam sandwich.

Aluminum foam sandwich (AFS) is an innovative sandwich material for designing lighter products and has many advantages such as high stiffness and high mechanical-energy absorption capacity. Although AFS is ready for series production, the number of use cases is low. A survey was carried out in order to identify the obstacles in the application of aluminum foam sandwich. This paper presents the results of the survey, derives the demand for a support method for designing with aluminum foam sandwich and shows various support options to simplify the application of the material.