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Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent times. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques like injection molding, casting etc.; AM unites advanced materials, machines, and software which will be critical for the fourth industrial revolution known as Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the parts. This paper reports the case studies of 3D-printed Automotive Fixtures which utilize computational methods (CAE), topology optimization and FDM constrains (build directions) to manufacture the part.

Simulations using computational techniques play a critical role in helping automotive industry adapt to light weighting and come up with future ready designs for maximizing the performance on cost and speed of manufacturing. As global legislation becomes increasingly stringent, light-weighting is a key element that will enable automotive OEMs to meet the emission goals towards net-zero future. Recent advancement in computational techniques like Topology Optimization have boosted the freedom of designers to reduce weight & cost of the part. This project discusses the development of computational models using physics-based software tools, and to validate the functional requirements to optimize the design using topology optimization techniques. The project also aims to reduce material consumption and manufacturing costs of the part while retaining its original stiffness.