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

该研究由EPSRC资助，旨在为汽车行业开发一种创新的新制造技术，因此符合制造技术研究领域。该研究的目的是研究将电子产品直接印刷到现有汽车部件上，并评估其质量和是否符合捷豹路虎标准，以及在最终使用条件下的长期性能和故障模式。实现这一目标的关键目标是：评估与复杂3D表面（不同区域和部件中的各种材料-塑料，橡胶，油漆等-未集成或已集成到汽车中）打印兼容的各种技术。向下选择技术以进行进一步评估，并列出这种方法中的挑战，以实现打印和制造。这将包括一个全面的文献调查和一套系统的范围实验。调查打印技术对已经制作的3D物体与各种基板等。这将需要一个全面的实验设计，以评估不同的打印材料和基板使用向下选择的打印方法（S）。可能需要对现有的印刷技术进行一些修改，以便能够在复杂的表面上进行印刷。三种不同应用的概念验证，A表面，身体部位外部，车身部件内部将被开发并用于性能分析。评估质量再现和捷豹路虎设计的合规性，并在汽车电子标准和GRADE审查中与捷豹路虎进行比较。研究汽车领域的印刷质量和预期寿命，包括详细的故障模式研究（FMEA）。.成果：-对知识的实质性贡献，将集中在以下方面：了解最合适的印刷技术，加工条件和材料，用于将电子产品直接印刷到现有的3D汽车结构上。印刷方法的技术限制和沉积电子产品的技术限制，包括可获得的质量。印刷电子产品的性能与JLR标准的性能以及长期故障模式和操作影响。-印刷显示器、照明或功能电子产品的工作原型，适用于三种不同的应用：A面、车身部件外部、车身部件内部。- 博士论文涉及现有零件或集成汽车领域的3D打印技术;包含挑战，材料，工艺，设备设计，制造方向，故障模式和建议。

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.