Innovative Design and 3D Fabrication of New Urban VeloCarsTM Bumper

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This project intends to develop an innovative bumper design with superior impact absorption capability and light weight for VeloCars invented by VeloMetro. VeloMetro is a Vancouver based start-up company that invented a type of enclosed bicycles, called VeloCars, to act as a functional alternative to the automobile for urban living. VeloCars are three-wheeled enclosed bicycles with electric assist that provide automobile functionality. VeloMetro believes offering a VeloCar sharing service will revolutionize personal transportation in urban areas. The VeloCars body design has been finalized and a prototype has been built. However, they are still facing one engineering design issue - the design and fabrication of bumper. Currently, VeloMetro has hired an automotive designer to design the outer profile of the bumper but the structure connecting the bumper profile and the concertina tube which is part of the main VeloCar body frame still needs to be designed, validated and fabricated. Due to the light weight requirement of this vehicle, VeloMetro is considering lattice structures to fill in the space between bumper profile and the concertina tubes to absorb impact shock at collisions. This research will investigate all suitable lattice structure on their capability of absorbing impact energy. The best one will be selected to form the impact absorbing structure in the design space. Since 3D printing is the primary manufacturing method to fabricate lattice structures, part consolidation, which is another unique capability enabled by 3D printing, will also be investigated to reduce bumper assembly in the final design. As a comparison, conventional foam and honey comb structure will also be investigated and compared to the lattice structure. Multiple design scenarios will be presented to VeloMetro with their manufacturability, cost and maintenance estimations for final decision.