Topology optimization-driven design of added rib architecture system for enhanced free vibration response of thin-wall plastic components used in the automotive industry

Abstract We are witnessing a relentless paradigm switch in the automotive industry, where traditional combustion engines are being progressively replaced with electric counterparts. In order to compensate for heavy electric engine technology, the plastic components usage in the interior parts of electric vehicles seems to be a reasonable strategy aligned with the lightweight trend as automotive industry top priority. Extremely thin plastic components (ultra-lightweight) attached to ribs-based architectures have been identified as an adequate solution offering a good balance between lightweight and structural/vibrational response of the overall composition. Still, they may yield detrimental features regarding thermal-induced deformations (i.e., warpage and shrinkage) associated with the typical mold injection process for their manufacturing. This paper aims to make use of topology optimization (TO) to determine the precise location of the added rib architecture system for enhanced vibration response of the overall plastic component (thin original plastic part and ribs architecture). Following a constant mass criteria, the topology optimization-driven design of the additional material is replaced with a more convenient ribs-based architecture component, showing a reasonable similarity from vibration standpoint. At a postprocessing stage, the design is analyzed subjected to typical static loading cases, to verify its stiffness properties. Finally, a warpage and shrinkage analysis of the design is carried out, verifying that the final design is not adversely affected according to standard considerations.