Integrated crash beams from BENTELER: Greater safety, less complexity

Paderborn, June, 5th. New crash management system combines protection, lightweight construction, and efficiency Every detail counts in vehicle development—especially when it comes to safety. With our integrated crash management system, BENTELER offers a solution that optimally combines protection, weight savings, and cost efficiency. 

Intelligent structure, impressive performance 

The new design combines upper and lower crash sections in a single structure. This reduces weld seams and heat-affected zones – and increases structural integrity. Advantages: 

• Higher energy absorption 

• Reduced complexity 

• Strong results in MPDB crash tests – with a view to top marks in E-NCAP and C-NCAP 

Stronger thanks to hot forming 

Particularly advantageous for electric vehicles: the crash beam made of hot-formed steel offers significantly higher strength than cold-formed alternatives – for maximum energy absorption and dissipation in the event of a crash. 

Two variants – both efficient: 

• Aluminum: approx. 15% lighter than conventional designs 

• Steel: up to 25% weight reduction 

Both meet the highest safety requirements. 

The steel variant is manufactured in a single production step. Laser-welded blanks enable targeted material distribution – and reduce production costs by up to 22%. 

Progress you can touch 

A current example: Our plant in Changchun, China, was specifically modernized in 2024 – including a highly automated production line for aluminum forming. This enables us to supply leading OEMs with integrated lightweight components of the highest quality. 

The integrated steel crash beam is also showing strong development: ongoing projects are making promising progress – clear proof of the future viability of our solution. 

Globally available – locally implemented 

With decades of expertise in metal processing, we develop solutions for customers worldwide – from the initial idea to series production.