Innovative Design and 3D Fabrication of New Urban VeloCarsTM Bumper

该项目旨在开发一种创新的保险杠设计，具有优越的冲击吸收能力和 由VeloMetro发明的轻量化VeloCars。VeloMetro是一家总部位于温哥华的初创公司 发明了一种封闭式自行车，称为VeloCars，作为汽车的功能性替代品 城市生活。VeloCars是一种三轮封闭式自行车，配有电动助力，为汽车提供动力 功能性。VeloMetro相信，提供VeloCar共享服务将使个人交通发生革命性变化 在城市地区。VeloCars的车身设计已经敲定，原型已经建造完成。然而，他们是 仍然面临着一个工程设计问题--保险杠的设计和制造。目前，VeloMetro已经聘请了 汽车设计师设计保险杠的外形，但连接保险杠的结构 型材和作为主要VeloCar车身框架一部分的Contina管仍需设计， 经过验证和捏造。由于这款车的重量要求很轻，VeloMetro正在考虑格栅 填充保险杠型材和Contina管之间的空间以吸收冲击冲击的结构 碰撞。这项研究将考察所有合适的晶格结构对其吸收冲击能力的影响 能量。在设计空间中选择最好的一种作为冲击吸收结构。自3D以来 印刷是制作点阵结构的主要制造方法，部分固结是另一种 通过3D打印实现的独特功能也将在最终研究中减少保险杠组装 设计。作为比较，还将对传统泡沫结构和蜂窝结构进行研究和比较 到晶格结构。将向VeloMetro展示多种设计方案及其可制造性， 最终决策的成本和维护估算。

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.