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One focus of automotive industry is to reduce the weight of cars especially for electric vehicles (EV). ROHACELL?composite structures offer a significant weight reduction potential without loosing mechanical performance. The first part of this presentation deals with the entire design process of structural sandwich parts with ROHACELL?cores. One focus is the static and dynamic (Crash) simulation of sandwich structures: ROHACELL?cores improve the energy absorption of crash relevant parts significantly. The second part of the presentation describes the different production processes of ROHACELL?sandwich structures. Injection (RTM, HRTM) and press moulding processes will be analyzed by means of serial application. Both, sandwich structures with thermoplastic and thermoset face sheets can be produced in a fast and economic way.