Topology optimization coupled with additive manufacturing offers tremendous opportunities to the automotive industry, evolving from prototyping and tooling towards end-use production. However, additive manufacturing for direct production of automotive components has been scarce, partially because of the sheer volume of automotive production. In this work, we explore the potential application of generative design optimization for the proper selection of the materials (metal versus polymer) and manufacturing processes (additive manufacturing versus stamping) to be used for both end-use and tooling parts. As a study for end-use application, radar mounting bracket was selected for design optimization for both additive manufacturing and stamping processes. As an example, for tooling application, engine assembly cam bracket was generatively redesigned to convert 40+ sub- assembly aluminum parts into a single part made of engineering polymer.
Learning Objectives:
- Upon completion, participants will be able to learn how to use generative design optimization tools to design or redesign a part based on the material, manufacturing process, cost, and
- Upon completion, participants will be able to learn the importance and ways towards wider adoption of generative design and additive manufacturing in automotive industry.
- Upon completion, participants will be able to learn the benefits and current limitations of additive manufacturing for automotive industry in terms of material, performance, and quality.
