The innovation potential of lightweight design in its scientific and technical foundations lies in the systematic, i.e. integrated and cross-material consideration of the process chains. This consideration is one of the main goals of dahlia project - Digital Technologies for Hybrid Lightweight Structures. The end-to-end digitalisation of the development, manufacturing and validation processes provides a first understanding of its process parameter-structure-property relationships, which is essential for developing a representative digital twin. To investigate these aspects in the design phase profiles made of aluminium alloy are exemplarily studied. Important aspects for the development of a digital twin are considered, such as a knowledge-based selection of design and simulation tools, their respective parametrisation and interface communication. First results are presented as well as the development aspects of a digital twin from its nominal offline form up to its specific application at a generic lightweight structure.