Abstract
This paper presents a fabrication and evaluation case study of a full-scale multi-material automotive semi-monocoque prototype. The prototype is composed of Variable Axial Composites (VAC) and aluminum inserts fabricated using nano-unevenness anodizing bonding technology. The basic design process involves multi-material anisotropic topology optimization and interpretation as manufacturing data. The 3D mold shape is manually defined and developable preform surfaces are placed to fill the mold cavity. The fiber path is automatically generated using the Turing Pattern algorithm based on the optimization data. The preforms are fabricated using the Tailored Fiber Placement (TFP) process, which uses a CNC embroidery machine to realize local fiber orientation control. The preforms are stacked in the mold and molded together with aluminum components by Vacuum Assisted Resin Transfer Molding (VaRTM). Experimental evaluations were conducted to assess the static stiffness of the prototype, and the results are compared with a conventional aluminum design.
