The objective of this project is to investigate the use of 3D printed polymer materials for use in Volvo trucks.
Sponsored by: Volvo
Team Members
Brian Chou Allison Spencer Jianhao Tang Timothy Prioleau William Flynn
Instructor: Asok Ray
Project Poster
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Project Video
Project Summary
Overview
It is essential to devise new ways to reduce the weight in cars and trucks. Volvo currently uses steel brackets and clamps to secure wires and cables within their cars. Carbon fiber composite materials are much lighter than steel, so substituting this new material where steel is currently used would be a step towards reducing the vehicle’s overall weight.
Objectives
Investigate the feasibility of additive manufacturing for Volvo Trucks
Identify engineering plastics that meet sponsor criteria
Verify the required mechanical and thermal properties of 3D printed materials
Investigate the unique possibilities associated with additive manufacturing
Approach
Produce a literature review to outline the material properties and manufacturing methods
Collect sponsor criteria and perform material selection accordingly
Print specimens with various infill extents and geometries
Perform mechanical and thermal testing to characterize the stress responses of those materials and geometries
Analyze data and input into a finite element analysis model to verify feasibility of design
Optimize to find the best material/geometry combinations for the application
Outcomes
Polycarbonate, ABS, and Nylon were all verified as feasible materials for the Volvo trucks application, with the latter requiring a thermal barrier coating to meet thermal criteria.
A means for optimization of part mass was discovered in the interaction of the infill % vs. strength and infill % vs manufacturing time relationships.
The project demonstrated the viability of additive manufacturing as means to introduce versatility into automotive part design and production.
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