Enhancing Design Flexibility in Electric Vehicles via Robotic extrusion-based Additive Manufacturing

Abstract

This article focuses on design-driven development of light electric vehicles for sustainable urban mobility. In response to EU directives to reduce city traffic, light electric vehicles are increasingly relevant for personal and commercial use, requiring innovative design and production strategies.Additive manufacturing (AM), particularly large-scale robotic extrusion, was explored as a tool to expand design freedom and optimize structural components. User needs and mobility challenges informed product requirements, guiding conceptual design, detailed component development, material selection, numerical simulations, and prototyping.The resulting vehicle demonstrates over 80% of components produced via additive technologies, validating robotic extrusion as a sustainable method that enhances design flexibility. This approach positions design at the core of innovation in urban electric mobility solutions.

Keywords: Product Design, Light Electric Vehicles, Additive Manufacturing, Robotic Extrusion

DOI: 10.54941/ahfe1007777