Assessment of crash performance of an automotive component made through additive manufacturing

Abstract

The objective of this study was to apply an innovative technique to manufacture a plastic automotive component to reduce its weight and costs, and guarantee its design was safe. A frontal impact sled test was simulated, and the damages to the occupant’s legs were assessed, with specific reference to the dashboard’s glove box. The replacement of the current glove box with a new component fabricated using additive manufacturing was analyzed to evaluate its passive safety performance in the event of an automobile accident. The materials analyzed were polyamide and polypropylene, both reinforced with 5% basalt. The stiffness of the system was previously characterized by reproducing a subsystem test. Subsequently, the same rating test performed by the Euro NCAP (New Car Assessment Program) was reproduced numerically, and the main biomechanical parameters required by the Euro NCAP were estimated for both the current and the additive production of the component.