Development of an Automated Fibre Placement-based Hybrid Composite Wheel for a Solar Powered Car

Abstract Substantial range, handling and acceleration improvements in high-performance vehicles can be achieved by weight reduction. An important area for weight reduction on a car is the wheels. A prototype carbon fibre/epoxy wheel has been developed using a combination of automated fibre placement (AFP) and hand layup for the Sunswift 7 solar car. A three-piece wheel design that utilises each process where best suited has been analysed and optimised using the ANSYS ACP PrepPost suite, manufactured, and mechanically tested. The wheel disc was produced using AFP and featured selective reinforcement in the form of spokes. The laminate for the disc has been optimised using CGTech VERICUT VCP and VCS to minimise gaps and overlaps and simulate the manufacturing process. The rim and tyre mounting region of the wheel have been manufactured using hand layup, and adhesively bonded to the disc. This hybrid manufacturing approach has demonstrated an advancement in the feasibility of combining traditional and automated composites manufacturing, providing insight into the manufacture of parts and products with complex shapes in the future.