Characterization of Additively Manufactured Lattice Structures with Continuous Carbon Fiber Reinforcement in the Automotive Industry

open_access
Open Access
Author:
Curotto, Nicholas
Area of Honors:
Mechanical Engineering
Degree:
Bachelor of Science
Document Type:
Thesis
Thesis Supervisors:
Nicholas Alexander Meisel, Thesis Supervisor
Anne Elizabeth Martin, Thesis Honors Advisor
Keywords:
Additive Manufacturing
Carbon Fiber
Lattice Structure
3D Printing
Markforged
FEA
Automotive
Abstract:
Additive manufacturing (AM) is an increasingly common method of creating complex parts with unique geometric and functional features that are otherwise difficult and expensive (if not impossible) to manufacture with traditional subtractive manufacturing methods. Rather than creating a part via taking excess material from a solid billet, additive manufacturing creates a part layer by layer, adhering the layers together to create a complete three-dimensional part for use in prototyping or final product. This creates the ability to harness computational lightweighting techniques such as topology optimization and latticing, and add features within the part such as embedded electrical components or integrated cooling channels. Another more recent advancement is the ability to combine the adhesion of layered polymers with the strength of continuous fibers, namely carbon fiber, fiberglass and ceramic, to create an even higher strength material with little to no increase in weight. However, the placement of fiber reinforcement is largely proprietary and algorithm based, leading to significant defects (areas where reinforcement should be laid but is omitted). In this study, additive manufacturing is used to combine the lightweighting features of latticing with the strength of continuous carbon fiber reinforcement to create a robust, high strength and lightweight part for the automotive industry. The study has two goals: The first is to quantify and categorize the defects present with the given parameters available; The second is to apply the best-case scenario lattice structure to an automotive case study part where a finite element analysis simulation will be conducted to determine the feasibility of the combined technology within the automotive industry. Together, these two goals combine to create the possibility of using this technology at a larger scale in the industry.