Use-Case 3: Segway

The third use-case deals with a self-balancing two-wheel scooter which is commonly named “Segway”. A design language was developed for a Segway with the engineering tool DC 43.
This Use-Case demonstrates the digitalization and integration of different domains of the product lifecycle:


The Segway is influenced by the user driven and legal requirements. Changes of requirements which are represented as changes of parameters lead to an automated adaption of the holistic model of the Segway. Manual reworking is hardly necessary any more.
Thus it is possible to calculate and generate a multitude of variants through changes of parameters within a very short time. The results serve as a means to elaborate optimal solutions regarding costs, quality or design criteria.


This use-case clearly demonstrates how a geometric model of a product can be generated automatedly by using simple geometric shapes like cylinders, cubes or spheres.

Cost calculation

For the first time, the costs are considered in detail in a design language. Additionally, a library was developed for the monetary estimation of the product. This library can be utilized for all other use-cases of the research project. At a very early time of the product lifecycle the costs can be estimated by modeling the costs of the design process. Furthermore, costs are illustrated more transparent.

The Siemens software Teamcenter Product Cost Management automatedly creates an extensive cost calculation with the result of the cost modelling in the UML-model of the product.

Bill of materials (BOM)

The use-case gives the possibility to automatedly generate a BOM. Especially, the assembly-planning and the production requires such a BOM. Changes in a model lead to a consistent change of the BOM.

Topology optimization

A library for topology optimization which was developed in use-case two is also used in the actual use-case. Moreover, a topology-optimized structure of the frame of the Segway was created automatedly and then printed by means of a 3D-printer.

Assembly concept planning

In the UseCase Segway, assembly concept planning is also integrated for a holistic and comprehensive view of the product life cycle. In the sense of the Digital Factory, libraries for processes and resources are developed. A static investment calculation is included in the resource library. Based on the generated BOM, the process chains can be generated with the corresponding resources. Depending on requirements such as the degree of automation or the required production output, assembly systems can be modeled and the output includes

  • a corresponding work plan,
  • a comprehensive economic efficiency calculation
  • and other assembly-relevant KPIs.

Based on this information, further decision processes can be digitally modelled, especially with the help of further software solutions.

Energy balance

With the aid of the software GaBi an energy balance for the Segway is performed which is also integrated in the holistic model. Thus an energy balance for each product variant can be generated automatedly. With that result it is possible to evaluate specific sectors of the product lifecycle regarding the energy balance and to perform an optimization where necessary.

Teaching concept

Within project- bachelor- and master-theses multiple variants of the Segway have been developed, both digitally and practically. Various lecture series cover the utilization of the DC 43 tool …and the digital product design. For this reason the Segway serves as an introductory example.