After the introduction of a bi-directional high-efficiency charger for electric vehicles in 2023, Renault Group and CEA have announced breakthroughs in on-board comfort technology, showcasing the synergy between their technical expertise and creativity.
After two years of intensive research and testing, resulting in the filing of approximately ten patents, the partners have developed a sophisticated mesh structure. Utilizing a single material and employing a single-stage 3D printing additive manufacturing process, this structure yields components with adaptive mechanical behavior and enhanced performance.
These innovative components, more potent, lighter, and customizable, can potentially replace conventional parts typically made from a combination of various materials, such as seats, backrests, armrests, and the center console.
The innovation is in employing cutting-edge digital methods and tools to design a strategically organized structure. Each strand comprising the lattice mesh structure can be parameterized in three dimensions, creating multi-layer networks of cells where each layer serves a distinct function with unique characteristics.
Even though they are intricately designed, the resulting monolithic and monomaterial parts are easier to manufacture, as they need only a single 3D printing operation without any assembly. This minimizes the carbon footprint and eliminates waste.
Crafted from TPU (Thermoplastic Polyurethane), these pioneering structures are recyclable. The structure pioneered by Renault Group and the CEA will open up the path for innovative applications, extending to areas where vehicle occupants frequently interact, such as front seats, door armrests, the center console, the rear bench seat, the steering wheel, and more.
” This innovation is the result of combining the R&D expertise of two major players in innovation, the CEA and Renault Group. It could enable us to offer customers a truly differentiating driving experience. We are continuing to explore its full potential, with a view to achieving even greater personalisation, but also to deriving new benefits for different areas of the vehicle” said Jean-François Salessy, Senior Vice President, Vehicle Synthesis and Upstream Technology, Renault Group Engineering
“The almost total freedom of design, the savings in materials and weight, the integration of functions and the reduction in manufacturing times all mean that additive manufacturing is a sector strongly supported by the CEA. This project with Renault Group confirms the strength of this discipline, which focuses on the development of new materials architected through design, their characterisation, and their integration into applications” said François Legalland, CEO of CEA-Liten.
