Exploratory study on Additive Manufacturing in Urban mobility

Abstract: This thesis report presents a comprehensive study on the design and development of an Additively manufactured Unit cell for car door panels, aiming to enhance impact resistance and reduce noise transmission to the vehicle cabin. In order to accomplish these goals, the study focuses on combining two novel techniques namely quasi-zero stiffness (QZS) structures and phononic crystals (both scattering and locally resonating type).The research begins by looking into similar research work, choosing appropriate unit cell topologies, and characterizing the materials suitable for AM. The performance of the unit cell design is then assessed using FEA simulations. To improve noise absorption and impact resistance, optimization techniques can be used.The experimental results demonstrate that the combination of QZS structures effectively enhances the unit cell’s ability to withstand impacts by redistributing and dissipating energy. Additionally, phononic crystal integration that employs both scattering and locally resonating mechanisms proves successful in attenuating noise transmission across a wide frequency range.The projected performance advantages of the 3D printed unit cell prototypes are confirmed by experimental testing. Measurements of noise absorption, impact resistance and mechanical testing confirm the viability of the suggested design.The findings of this research contribute to the advancement of additive manufacturing techniques in the automotive industry. The proposed unit cell design for 3D printing exhibits potential for enhancing occupant safety and acoustic comfort in automotive door panels. The proposed technologies have the potential to be further optimized and integrated to produce enhanced automotive door panels with higher impact resistance and noise reduction capabilities