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IDeS + TRIZ: Sustainability Applied to DfAM for Polymer-Based Automotive Components.

Christian Leon-Cardenas1, Giampiero Donnici1, Alfredo Liverani1

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Summary

This study explores sustainable additive manufacturing using Manufacturing 4.0 tools to redesign a vehicle suspension arm. The innovative approach achieved over 80% weight reduction, optimizing performance and reducing energy consumption.

Keywords:
IDeSTRIZadditive manufacturingproduct designproduct reverse engineering

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Area of Science:

  • Engineering
  • Materials Science
  • Manufacturing Technology

Background:

  • Additive manufacturing (AM) and Manufacturing 4.0 concepts are transforming industrial production.
  • Optimizing component design for performance, cost, and sustainability is crucial in automotive applications.

Purpose of the Study:

  • To investigate the integration of Manufacturing 4.0 tools for sustainable additive manufacturing.
  • To redesign a vehicle suspension arm using innovative techniques to enhance performance and reduce environmental impact.

Main Methods:

  • Design for Additive Manufacturing (DfAM) principles applied with Manufacturing 4.0 tools.
  • Computer-Aided Engineering (CAE) with Finite Element Method (FEM) analysis and Computer-Aided Manufacturing (CAM).
  • Integration of the Innovative Design of Structures (IDeS) method and TRIZ methodology.

Main Results:

  • A redesigned composite vehicle suspension arm using Fused Deposition Modeling (FDM) sourced processes.
  • Achieved a weight reduction exceeding 80% compared to traditional components.
  • Demonstrated reduced material consumption, labor, and scrap generation, leading to lower energy use.

Conclusions:

  • The study validates the feasibility of FDM-sourced additive manufacturing for complex automotive parts.
  • The integrated design approach significantly enhances component sustainability and optimizes production efficiency.
  • This holistic approach contributes to more sustainable manufacturing practices and reduced vehicle energy consumption.