Additively Manufactured Wheel Suspension System with Integrated Conductions and Optimized Structure

Society's growing environmental awareness and increasing urbanisation require new and innovative vehicle concepts. The use of additive manufacturing (AM) expands the design freedom in component development. In this paper, these are utilised to further develop a front axle suspension for a new type of modular vehicle concept. The wheel suspension components are optimised on the basis of a new method that has already been applied in previous work. This is based on industry-standard load cases for the strength design of the components, as well as the available installation space determined for the design of the suspension components and the suitable configuration of the suspension components. The component geometries identified using numerical methods that are suitable for the force flow are optimised with regard to the integration of information, energy and material-carrying lines in the control arms and the lines are used as load-bearing structures as extensively as possible. High-strength light metals are used to minimise the component masses. Openings are provided in the components for routing electrical cables. The fluid transport is realised using lines integrated into the wishbones. The final geometries of the suspension components are then validated by a finite element analysis (FEA) of the entire suspension model. The result of the method used are lighter suspension components with a maximum degree of functional integration. The increased functional integration reduces the required installation space, which improves the vehicle package and achieves greater front wheel clearance, which increases the possible steering angles and thus improves maneuverability. The reduction in unsprung masses can improve driving behaviour and has a positive effect on the vehicle's energy consumption. In addition, the integration of the conductions section simplifies the assembly of the front axle suspension.