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Master’s in Lightweight Structures and Materials Engineering

Online master's programme of 1,900 hours in lightweight structures and materials engineering. 12 modules covering materials selection, aluminium, magnesium, titanium and composites, structural analysis and optimisation, fatigue, manufacturing, joints and validation under Eurocode 9, with an assigned technical tutor.

Duration1900 h
ModeOnline
LanguageEnglish
Start datesSet by the faculty
AwardSEIUM Institute diploma
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Learning outcomes

What you will be able to do

01

Select lightweight materials using performance indices.

02

Design aluminium, magnesium, titanium and composite structures.

03

Apply topology and thickness optimisation to chassis parts.

04

Calculate the fatigue life of welded and cast structures.

05

Choose manufacturing processes suited to each material.

06

Validate lightweight structures through testing.

07

Develop a lightweight structural component for a two-wheeled vehicle.

Profile

Who it's for

  • Lightweight structures engineers at motorcycle and bicycle manufacturers.
  • Materials engineers working with metals and composites.
  • Structural analysis engineers using FEM.
  • Fatigue and durability engineers.
  • Casting and forging process engineers.
  • Chassis development engineers.
  • Engineering or science graduates aiming to join motorcycle manufacturers.
Standards & tools

What you'll work with

  • EN 1999-1-1 (Eurocode 9) (design of aluminium structures, general rules)
  • EN 1999-1-3 (aluminium structures susceptible to fatigue)
  • ISO 6892-1 (tensile testing of metallic materials)
  • ISO 12107 (statistical planning and analysis of fatigue data)
  • ISO 5817 (quality levels for imperfections in welds)
  • ISO 3834-2 (comprehensive quality requirements for fusion welding)
  • ASTM E466 (force-controlled constant-amplitude axial fatigue tests)
  • ASTM D3039 (tensile properties of polymer matrix composites)
  • Altair OptiStruct
  • Abaqus
  • nCode DesignLife
  • Altair Inspire
  • Granta Selector
Syllabus

12 modules · 1900 h

  1. 1.1Impact of mass on performance
  2. 1.2Sprung and unsprung mass
  3. 1.3Rotational inertia of wheels
  4. 1.4Specific stiffness of materials
  5. 1.5Cost versus mass saving
  6. 1.6Life cycle and carbon footprint
  7. 1.7Components with the greatest potential
  8. 1.8Lightweighting strategies
  9. 1.9Mass benchmarking
  10. 1.10Case study: mass audit of a sports motorcycle
  1. 2.1Ashby charts
  2. 2.2Performance indices
  3. 2.3Cost and process constraints
  4. 2.4Materials databases
  5. 2.5Multi-criteria materials selection
  6. 2.6Materials for frames
  7. 2.7Materials for wheels
  8. 2.8Materials for bodywork
  9. 2.9Materials substitution
  10. 2.10Practical exercise: selection for a subframe
  1. 3.16000 and 7000 series
  2. 3.2Casting alloys
  3. 3.3T6 heat treatments
  4. 3.4Profile extrusion
  5. 3.5Forging of suspension parts
  6. 3.6Aluminium welding
  7. 3.7Corrosion and protection
  8. 3.8Design according to Eurocode 9
  9. 3.9Fatigue of aluminium joints
  10. 3.10Laboratory: tensile test of welded aluminium
  1. 4.1Magnesium die casting
  2. 4.2Forged magnesium wheels
  3. 4.3Titanium in exhausts and fasteners
  4. 4.4Chromium-molybdenum steels
  5. 4.5High-strength steels
  6. 4.6Galvanic corrosion in mixed joints
  7. 4.7Protective anti-corrosion coatings
  8. 4.8Cost and availability
  9. 4.9Safety in magnesium machining
  10. 4.10Case study: magnesium versus aluminium wheel
  1. 5.1Carbon frames and swingarms
  2. 5.2Carbon wheels
  3. 5.3Fairings and cosmetic parts
  4. 5.4Thermoplastic matrix composites
  5. 5.5Natural fibre composites
  6. 5.6Composite-to-metal joints
  7. 5.7Impact damage
  8. 5.8Small-series manufacturing
  9. 5.9Product repairability
  10. 5.10Practical exercise: lamination of a structural mudguard
  1. 6.1Load cases of a motorcycle
  2. 6.2Braking and bump loads
  3. 6.3FEM models of frames
  4. 6.4Torsional and lateral stiffness
  5. 6.5Tube buckling
  6. 6.6Welded joints in FEM
  7. 6.7Analysis of cast parts
  8. 6.8Model validation
  9. 6.9Results post-processing
  10. 6.10Workshop: FEM model of a swingarm
  1. 7.1Topology optimisation of the part
  2. 7.2Shape optimisation
  3. 7.3Thickness optimisation
  4. 7.4Manufacturing constraints
  5. 7.5Multi-material optimisation
  6. 7.6Fatigue-based optimisation
  7. 7.7Interpretation of results
  8. 7.8Redesign for manufacturing
  9. 7.9Available commercial tools
  10. 7.10Laboratory: optimisation of a triple clamp
  1. 8.1S-N curves of lightweight materials
  2. 8.2Fatigue of welds
  3. 8.3IIW fatigue recommendations
  4. 8.4Fatigue of castings
  5. 8.5Cumulative fatigue damage
  6. 8.6Loads measured on the road
  7. 8.7Statistical analysis according to ISO 12107
  8. 8.8Fatigue in composites
  9. 8.9Safety factors
  10. 8.10Practical exercise: fatigue life of a welded frame
  1. 9.1Low-pressure casting
  2. 9.2Die casting
  3. 9.3Hot forging
  4. 9.4Tube hydroforming
  5. 9.5TIG and MIG welding
  6. 9.6Friction stir welding
  7. 9.7Metal additive manufacturing
  8. 9.8Weld quality control to ISO 5817
  9. 9.9Cost per process
  10. 9.10Case study: process for a perimeter frame
  1. 10.1Bolted joints and their calculation
  2. 10.2Tightening torques and preload
  3. 10.3Structural adhesive joints
  4. 10.4Rivets and mechanical joints
  5. 10.5Joining dissimilar materials
  6. 10.6Fatigue of bolted joints
  7. 10.7Corrosion in joints
  8. 10.8Design for disassembly
  9. 10.9Joint testing
  10. 10.10Laboratory: test of an adhesive joint
  1. 11.1Bench stiffness tests
  2. 11.2Multiaxial fatigue tests
  3. 11.3Impact tests
  4. 11.4Corrosion tests
  5. 11.5Strain gauging of components
  6. 11.6Test-to-FEM correlation
  7. 11.7Wheel tests
  8. 11.8Road tests
  9. 11.9Acceptance criteria
  10. 11.10Practical exercise: validation plan for a swingarm
  1. 12.1Component selection
  2. 12.2Requirements and loads
  3. 12.3Material selection
  4. 12.4Structural optimisation of the component
  5. 12.5Fatigue calculation
  6. 12.6Manufacturing process
  7. 12.7Validation plan
  8. 12.8Mass and cost balance
  9. 12.9Master's Thesis report
  10. 12.10Master's Thesis: defence before a panel
Methodology, software & labs

How you'll learn

100% online training on the SEIUM campus, with downloadable material, recorded classes and an assigned technical tutor. No fixed timetables: you progress at your own pace within the intake, making it compatible with work.

Each module combines theory, guided reading of the original standard and applied exercises. The working software is Altair OptiStruct, Abaqus, nCode DesignLife, Altair Inspire and Granta Selector, in free, academic or evaluation versions. Tests are studied using real procedures: mass optimisation of an aluminium swingarm, a fatigue test of a welded frame joint, and comparison of magnesium, aluminium and carbon alternatives for a wheel. Assessment is continuous by module, plus the final Master's Thesis.

Standards covered: EN 1999-1-1 (Eurocode 9), EN 1999-1-3, ISO 6892-1, ISO 12107, ISO 5817, ISO 3834-2, ASTM E466, ASTM D3039.

Assigned technical tutor:every module ends with a deliverable that your tutor marks individually.
Standards-based learning:guided reading of EN 1999-1-1 (Eurocode 9), EN 1999-1-3, ISO 12107 and ISO 5817 applied to real cases, not as a theoretical annex.
Industry software:Altair OptiStruct, Abaqus, nCode DesignLife, Altair Inspire and Granta Selector, in free, academic or evaluation versions.
Master's Thesis with defence:A lightweight structural component for a two-wheeled vehicle, from material selection to validation plan, defended before a panel.
Flexible format:100% online, no fixed timetables, compatible with full-time work.
Capstone project

Build it end to end

Your final project follows the real engineering workflow, step by step, reviewed by your tutor.

Component, requirements and loads
Select the component and define its requirements and load cases.
Material selection
Choose the material using performance indices and cost constraints.
Optimisation and fatigue
Optimise the component structurally and calculate its fatigue life.
Manufacturing and validation
Define the manufacturing process and the validation plan.
Master's Thesis
Present the component with its mass and cost balance, defended before a panel.
Career opportunities

Where this takes you

Lightweight Structures EngineerMaterials EngineerStructural Analysis EngineerFatigue EngineerCasting and Forging Process EngineerChassis Development Engineer
Admissions & scholarships

Requirements

  • A university degree in engineering, science or architecture, or equivalent demonstrable professional experience.
  • An internet connection and a computer capable of running the programme's software.
  • English sufficient to read technical standards.

Ready to start?

Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.

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FAQ

Frequently asked questions

The programme totals 1,900 hours over 12–14 months. You set your own pace within each intake, and your tutor helps you plan the workload around your job.

You work with Altair OptiStruct, Abaqus, nCode DesignLife, Altair Inspire and Granta Selector, using free, academic or evaluation versions. Your tutor indicates the free alternative wherever one exists.

A SEIUM Institute diploma, awarded on passing the continuous assessment and the Master's Thesis. It is SEIUM's own qualification, not an official state degree; its recognition depends on the programme completed and the regulations of each country.

Yes. Modules passed in a course or postgraduate diploma in the same area are recognised in the higher programme. Ask about the recognition policy when you enrol.

A university degree in engineering, science or architecture (or equivalent professional experience), a computer able to run the programme's software, and English sufficient to read technical standards.

Start dates are set by SEIUM's faculty for each intake. Our admissions team will confirm the next available date when you apply.

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