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

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.