Smart Door

Motivation

© Fraunhofer IWU

Trend:

Individualization & functional enhancement in automotive (40.000 individualized vehicles per day at VW)

Challenge:

Variety of variants with decreasing batch sizes

Aim:

Differentiation and increased efficiency of the production by means of printing and laser technologies demonstrated on a car door: printed conductive paths simplifying and lightening the   wiring harness, embedding sensors and control elements

Results Smart Door

Production of the Future | Production Technologies for Functional Integration

 

■ Economic approach to individualization of mass production products  

 


Successful Functionalization of Metallic Components

 

■ Printing of robust and deformable insulation layers and conducting paths on aluminum which are functional after metal forming

■ Connection technology from printed pattern to standard connectors

 

Successful Functionalization of Thermoplastic Components

 

■ Printing of electrodes and piezo active layer for pressure sensitive button application + LED lighting

■ Digital production of vias / through-hole via laser

■ Digital manufactured plug compatible interface

■ Simulation of illumination for individualized button layouts

 

Hybrid Integration of Ultrasonic Transducers for Near Field Sensing

 

■ Application of piezo electronic discs onto aluminum sheets

■ Optimization of resonance frequency and sound pressure level by laser ablation of the metallic substrate

■ Maximum sound pressure level @ 38,9 kHz à suitable as ultrasonic proximity sensor

 

 

Printing on 3D Parts by Robotics

 

■ Robot supported printing technology for the production of conducting paths on 3D parts

■ Closed CAD-CAM chain for fast change of print layouts on 3D parts