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

这项研究由EPSRC资助，旨在为汽车行业开发一种创新的新制造技术，因此适合制造技术研究领域。本研究的目的是研究将电子元件直接打印到现有的汽车部件上，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（不同区域和部件的各种材料-塑料，橡胶，油漆等-未集成或已集成到汽车上）打印兼容的各种技术。下拉选择进一步评估的技术，并列出这种方法中的挑战，以实现印刷和制造。这将包括一个全面的文献调查和系统的范围界定实验。研究用各种基材制作3D物体的打印技术。这将需要一个全面的实验设计来评估不同的印刷材料和基材，使用下选择的印刷方法。为了能够在复杂的表面上打印，可能需要对现有的打印技术进行一些修改。将在三种不同的应用上进行概念验证，A面，车身部分外部，车身部分内部，并用于性能分析。评估可实现的质量复制和JLR设计的合规性，并与JLR在汽车电子标准和GRADE审查方面的性能进行比较。研究汽车领域的印刷质量和预期寿命，包括详细的失效模式研究（FMEA）。成果：-对知识的实质性贡献将集中在以下方面：了解最合适的打印技术、加工条件和材料，以便将电子设备直接打印到现有的3D汽车结构上。印刷方法的技术限制和沉积电子器件的技术限制，包括可获得的质量。与JLR标准相比，印刷电子产品的性能以及长期失效模式和运行影响。-打印显示器，照明或功能性电子产品的工作原型，用于三种不同的应用，A面，车身外部，车身内部。-关于现有零件或集成汽车领域3D打印技术的博士论文；包含挑战，材料，工艺，设备设计，制造方向，失效模式和建议。

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.