3D Printing of Electronics and Displays onto Existing Automotive Components and Structures

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This research is funded through EPSRC and aims to develop an innovative new manufacturing technology for the automotive sector, and thus fits in the Manufacturing Technologies research area.The aim of this research is to investigate the direct printing of electronics onto pre-existing automotive components and to assess their quality and compliance with Jaguar Land Rover standards and their long-term performance and failure modes under end-use conditions. The key objectives to achieve this aim are:Evaluate various techniques compatible with printing onto complex 3D surfaces (various materials - plastics, rubber, paint, etc. in different areas and parts - not integrated or already integrated into car). Down-select technique(s) for further evaluation, and listing of the challenges in such a methodology to enable printing and manufacturing. This will comprise a comprehensive literature survey and systematic set of scoping experiments.Investigate printing techniques on to already made 3D objects with various substrates etc. This will require a comprehensive experimental design to evaluate different printed materials and substrates using the down-selected printing method(s). Some modification of the existing printing technologies may be necessary to enable printing onto complex surfaces. A proof of concept on three different applications, A-surface, body part exterior, body part interior will be developed and used for performance analysis.Assessment of the compliance to quality reproduction and JLR design that is achievable and study performance in comparison with JLR in car electronics standards and GRADE reviews.Study of quality of printing and life expectancy in automotive domain including a detailed Failure mode study (FMEA).Outcomes:- A substantive contribution to knowledge that will focus on the following:Understanding of the most appropriate printing technology, processing conditions and materials for the direct printing of electronics onto existing 3D automotive structures.The technical limitations of the printing method and those of the deposited electronics, including the quality obtainable.The performance of the printed electronics against that of JLR standards and the long-term failure modes and effects operating.- A working prototype of a printed display, lighting or functional electronics on three different applications, A-surface, Body part exterior, Body part interior. - A PhD thesis into 3D printing techniques for existing parts or integrated car automotive domain; containing challenges, materials, process, equipment design, manufacturing direction, failure modes and recommendations.