concept
arpa.e
local motors
ae
concept
algorithm enhanced structural design
concept ae combines multiple weight and safety innovations through three key technological advances: .........................................................................Algorithmically controlled progressive additive manufacture ............................................................................................................................................................................next generation graphene nanotube weave ............................................................................................................Electroactive polymer and non newtonian components
concept
ae concept for litecar challenge 2015
arpa.e
local motors
ae
concept
algorithm enhanced structural design
structural component design for concept ae is based around algorithmically controlled additive manufacture. a particular additive blend or metal alloy incorporated to the composite vehicle structure optimises the material properties, for example flexibility in a suspension unit or strength in a safety cell. ip control of prime ae algorithms potentially ends cross-industry comparisons of component performance.
algorithm ae advanced engineering:
(x3y3z)
AE enhances automotive structural design
(2xy3)
at any given point in the structure, two base algorithms in the 3D print controller instruct the nozzle drivers:
(3y2)
..............................a swarm function determines the shape of the internal structure, algorithmically combining complex sim data of performance vs weight.
AE exploits next generation additive print hardware ae enables change in vehicle packaging to improve safety
......................the second function alters the additive compound ratios and blend depending on the form determined by the swarm algorithm, continually optimising the material properties.
ae redefines the parameters of lightweight
d%
b% a%
c%
h% e%
f%
g%
j%
Through algorthmically controlled optimisation of both form and material-constituents-relative-toform it is then possible to create the highest strength to weight ratio for a given component, dramatically reducing base structural weight. each optimal component algorithm developed by a research team can then be licensed as IP, funding the r&d of further advances in ae.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
concept ae utilises next generation nanotube engineered fibres to mitigate bodywork and glazing where possible. pressed metallic body fabrications can constitute as much as 25% of vehicle weight. nanotube graphene net offers up to a 150-fold strength to weight ratio improvement over steel. as such, nanotube research in concept ae drastically reduces the weight of non structural components.
nano-weave concept ae nano-tech: nanotube weave mitigates bodywork on concept ae. nanoweave removes all non laminate glazing from ae.
...................................................................bundles of ultra lightweight nanotube graphene fibres are woven into a net structure. Utilised in non structural locations on the car, the graphene net weatherproofs concept ae and protects occupants from road debris. ............................................aesthetic form is facilitated by electroactive seams woven into the fabric. the sculptural form developed by the design team is then manipulated through these seams, as bones supporting a bat's wing give it shape.
nanoweave enhances next generation auto aesthetics.
areas of high impact glass laminate are replaced with an iridium coated polycarbonate, reducing weight at no cost to safety. Attachment points for the nanotube net are adhesively mounted to the polycarb, removing heavy hard fasteners.
to negate any loss of vision through the nanotube weave a coating of nanopixel substrate on the inner skin provides an na n augmented view out from the op i vehicle. xel
arpa.e
local motors
ae
concept
algorithm enhanced
to facilitate component reduction concept AE makes use of future electroactive material properties. by consolidating multiple components such as the anti-roll system into the material properties of other areas. this increases the efficiency with which the unavoidable weight of essential structures can be utilised.
structural design
Electroactive
airbags were not always the lead automotive safety system. audi released the procon 10 system in 1986, designed to retract the steering wheel in a crash situation.
concept ae electroactive: electroactive polymers allow ae component consolidation.
vs
integration into h.i. systems increases concept ae comfort.
..............................................this inspired us to look at ways in which the steering wheel could become a safety feature, rather than a danger. future research into electroactive polymers gives concept AE a crumple steering wheel. in a crash scenario charge to the material is cut, creating a collapsing safety wheel and saving weight from airbag systems.
ea materials lead to optimal structure efficiency in ae. electroactive polymer construction allows the steering wheel and column to collapse in a crash scenario.
reactive crash structure utilisation (see 'safety'). aesthetic form design in the nanotube weave is actuated via electroactive seams.
to isolate occupants from road imperfections bioengineered pliant outriggers are incorporated to the chassis structure. the inculsion of electroactive polymers also gives the outrigger anti roll properties, stiffening to counteract lateral g force.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
ae is focused on redefining lightweight. through precise application of load optimised material in an innovative vehicle package a new class of ultra lightweight automotive structures can be developed. incorporating phase change materials to the concept offers weight reduction through component consolidation, reducing individual structures as well as their weight penalty.
ae lightweight ae is fundamentally lightweight: ae enables weight to strength optimised structural design. high acuity of control over rate of material application.
n kg
component reduction through function consolidation. innovative design redefining body material selections. n
natural bone structure strength modelling concept ae utilises a three tier approach to weight reduction :
kg
..............algorithmic additive control optimises structural efficiency. ..................................................innovative material applications offer component consolidation possibilities. .....................................................future commercial nanotechnology eliminates non structural metal fabrications.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
through structural optimisation ae enables a new level of safety in automotive design. offering precise control over material strength and deformation properties the entire ae concept structure is modelled to effectively absorb and oppose impact forces. Combined with a fundamental packaging redesign the ae concept ushers in the next generation of occupant protection.
ae safety ae ensures safety: non newtonian reactive crash structure materials. a fundamental safety-focused packaging redesign. optimised crash and protective structures. flawless incorporation of safety components.
the front screen is radiused away from the occupants, and driver h point is packaged as far rearward from the screen as possible.
rear occupants face backwards, reducing weight by sharing a central seat bracket, and reducing point force in an impact. by combining additive manufacture with non newtonian materials concept ae incorporates reactive crash structures altering material strength depending on the force applied.
a constant rate of deceleration is key to an effective safety system. low force resistance high force resistance high energy impact
mid energy impact
low energy impact
8.0 LITRE
an eggshell form distributes impact force evenly reducing material thickness requirements further reducing weight.
B
B E N T L E Y QUAD TURBO
classic automotive package imbalanced force dissipation.
concept ae eggshell chassis dissipates force evenly.
arpa.e
local motors
ae
concept
high force deformation
low force deformation
algorithm enhanced structural design
ae safety concept ae utilises an eggshell chassis to achieve the highest possible impact force dissipation for a given weight of structure
mapping of passive crash protection structures in concept ae demonstration
as a result occupants are packaged within a reduced crumple zone. this is potentially a risk in high speed high energy collisions to mitigate this risk, the structural additive algorithm blends a non newtonian compound into the outer layers of passive impact resistance the proportion of non newtonian compound determines the impact force at which the shear resistant properties of the material increase. inspired by recent anti-ballistic testing of non newtonian materials, this reactant approach to force dissipation minimises the volume and weight of material necessary to ensure a protective safety cell.
passive impact structure
reactive impact structure
mapping of reactive crash protection structures in concept ae demonstration
arpa.e
local motors
algorithm enhanced structural design
innovative manufacture is the driver behind concept ae. the main processes additive manufacturing, vacuum forming and nanotube weave - all have low set up and overhead costs, paving the way for a new generation of open source maker factories. although not a key requirement a clean-slate auto package redesign for ae also eliminates the most environmentally harmful build zones: metal press and paintshop.
manufacture al loc s tor mo
na n op i xel
40 0 2
ae
concept
20
20 estimation of commercial component feasibility
arpa.e
local motors
ae
concept
algorithm enhanced
concept ae specification correct at time of publication manufacturer retains right to alteration without notification. all open source AE development is undertaken at own risk, ae ltd accepts no responsibility for non ae affiliated design modification. it is at user discretion to determine algorithm source.
structural design
ae concept spec concept ae target specification
45HP air COOLED 2 x dyson digital brushless motor in hub outer motor casings structural battery weave chassis
3f 3r all 3psb
c
r n/p*d
e
f
d
1f 1r pinion transmission electric virtual lsd active torque vectoring traction 3d printed structural wiring loom in hub steering motors ecu governed virtual steering rack regen fr disc rear brakes
*
three second hold to park
a b
vw golf 7 for comparison 1:10 scale at 100 percent a..........wheelbase...........................................................................................................................................................3120mm b..........length............................................................................................................................................................4395mm c..........height............................................................................................................................................................1750mm d..........gvw............................................................................................................................................................
local motors
ae
concept
algorithm enhanced structural design
concept ae combines multiple weight and safety innovations through three key technological advances: .........................................................................Algorithmically controlled progressive additive manufacture ............................................................................................................................................................................next generation graphene nanotube weave ............................................................................................................Electroactive polymer and non newtonian components
concept
ae concept for litecar challenge 2015
arpa.e
local motors
ae
concept
algorithm enhanced structural design
structural component design for concept ae is based around algorithmically controlled additive manufacture. a particular additive blend or metal alloy incorporated to the composite vehicle structure optimises the material properties, for example flexibility in a suspension unit or strength in a safety cell. ip control of prime ae algorithms potentially ends cross-industry comparisons of component performance.
algorithm ae advanced engineering:
(x3y3z)
AE enhances automotive structural design
(2xy3)
at any given point in the structure, two base algorithms in the 3D print controller instruct the nozzle drivers:
(3y2)
..............................a swarm function determines the shape of the internal structure, algorithmically combining complex sim data of performance vs weight.
AE exploits next generation additive print hardware ae enables change in vehicle packaging to improve safety
......................the second function alters the additive compound ratios and blend depending on the form determined by the swarm algorithm, continually optimising the material properties.
ae redefines the parameters of lightweight
d%
b% a%
c%
h% e%
f%
g%
j%
Through algorthmically controlled optimisation of both form and material-constituents-relative-toform it is then possible to create the highest strength to weight ratio for a given component, dramatically reducing base structural weight. each optimal component algorithm developed by a research team can then be licensed as IP, funding the r&d of further advances in ae.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
concept ae utilises next generation nanotube engineered fibres to mitigate bodywork and glazing where possible. pressed metallic body fabrications can constitute as much as 25% of vehicle weight. nanotube graphene net offers up to a 150-fold strength to weight ratio improvement over steel. as such, nanotube research in concept ae drastically reduces the weight of non structural components.
nano-weave concept ae nano-tech: nanotube weave mitigates bodywork on concept ae. nanoweave removes all non laminate glazing from ae.
...................................................................bundles of ultra lightweight nanotube graphene fibres are woven into a net structure. Utilised in non structural locations on the car, the graphene net weatherproofs concept ae and protects occupants from road debris. ............................................aesthetic form is facilitated by electroactive seams woven into the fabric. the sculptural form developed by the design team is then manipulated through these seams, as bones supporting a bat's wing give it shape.
nanoweave enhances next generation auto aesthetics.
areas of high impact glass laminate are replaced with an iridium coated polycarbonate, reducing weight at no cost to safety. Attachment points for the nanotube net are adhesively mounted to the polycarb, removing heavy hard fasteners.
to negate any loss of vision through the nanotube weave a coating of nanopixel substrate on the inner skin provides an na n augmented view out from the op i vehicle. xel
arpa.e
local motors
ae
concept
algorithm enhanced
to facilitate component reduction concept AE makes use of future electroactive material properties. by consolidating multiple components such as the anti-roll system into the material properties of other areas. this increases the efficiency with which the unavoidable weight of essential structures can be utilised.
structural design
Electroactive
airbags were not always the lead automotive safety system. audi released the procon 10 system in 1986, designed to retract the steering wheel in a crash situation.
concept ae electroactive: electroactive polymers allow ae component consolidation.
vs
integration into h.i. systems increases concept ae comfort.
..............................................this inspired us to look at ways in which the steering wheel could become a safety feature, rather than a danger. future research into electroactive polymers gives concept AE a crumple steering wheel. in a crash scenario charge to the material is cut, creating a collapsing safety wheel and saving weight from airbag systems.
ea materials lead to optimal structure efficiency in ae. electroactive polymer construction allows the steering wheel and column to collapse in a crash scenario.
reactive crash structure utilisation (see 'safety'). aesthetic form design in the nanotube weave is actuated via electroactive seams.
to isolate occupants from road imperfections bioengineered pliant outriggers are incorporated to the chassis structure. the inculsion of electroactive polymers also gives the outrigger anti roll properties, stiffening to counteract lateral g force.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
ae is focused on redefining lightweight. through precise application of load optimised material in an innovative vehicle package a new class of ultra lightweight automotive structures can be developed. incorporating phase change materials to the concept offers weight reduction through component consolidation, reducing individual structures as well as their weight penalty.
ae lightweight ae is fundamentally lightweight: ae enables weight to strength optimised structural design. high acuity of control over rate of material application.
n kg
component reduction through function consolidation. innovative design redefining body material selections. n
natural bone structure strength modelling concept ae utilises a three tier approach to weight reduction :
kg
..............algorithmic additive control optimises structural efficiency. ..................................................innovative material applications offer component consolidation possibilities. .....................................................future commercial nanotechnology eliminates non structural metal fabrications.
arpa.e
local motors
ae
concept
algorithm enhanced structural design
through structural optimisation ae enables a new level of safety in automotive design. offering precise control over material strength and deformation properties the entire ae concept structure is modelled to effectively absorb and oppose impact forces. Combined with a fundamental packaging redesign the ae concept ushers in the next generation of occupant protection.
ae safety ae ensures safety: non newtonian reactive crash structure materials. a fundamental safety-focused packaging redesign. optimised crash and protective structures. flawless incorporation of safety components.
the front screen is radiused away from the occupants, and driver h point is packaged as far rearward from the screen as possible.
rear occupants face backwards, reducing weight by sharing a central seat bracket, and reducing point force in an impact. by combining additive manufacture with non newtonian materials concept ae incorporates reactive crash structures altering material strength depending on the force applied.
a constant rate of deceleration is key to an effective safety system. low force resistance high force resistance high energy impact
mid energy impact
low energy impact
8.0 LITRE
an eggshell form distributes impact force evenly reducing material thickness requirements further reducing weight.
B
B E N T L E Y QUAD TURBO
classic automotive package imbalanced force dissipation.
concept ae eggshell chassis dissipates force evenly.
arpa.e
local motors
ae
concept
high force deformation
low force deformation
algorithm enhanced structural design
ae safety concept ae utilises an eggshell chassis to achieve the highest possible impact force dissipation for a given weight of structure
mapping of passive crash protection structures in concept ae demonstration
as a result occupants are packaged within a reduced crumple zone. this is potentially a risk in high speed high energy collisions to mitigate this risk, the structural additive algorithm blends a non newtonian compound into the outer layers of passive impact resistance the proportion of non newtonian compound determines the impact force at which the shear resistant properties of the material increase. inspired by recent anti-ballistic testing of non newtonian materials, this reactant approach to force dissipation minimises the volume and weight of material necessary to ensure a protective safety cell.
passive impact structure
reactive impact structure
mapping of reactive crash protection structures in concept ae demonstration
arpa.e
local motors
algorithm enhanced structural design
innovative manufacture is the driver behind concept ae. the main processes additive manufacturing, vacuum forming and nanotube weave - all have low set up and overhead costs, paving the way for a new generation of open source maker factories. although not a key requirement a clean-slate auto package redesign for ae also eliminates the most environmentally harmful build zones: metal press and paintshop.
manufacture al loc s tor mo
na n op i xel
40 0 2
ae
concept
20
20 estimation of commercial component feasibility
arpa.e
local motors
ae
concept
algorithm enhanced
concept ae specification correct at time of publication manufacturer retains right to alteration without notification. all open source AE development is undertaken at own risk, ae ltd accepts no responsibility for non ae affiliated design modification. it is at user discretion to determine algorithm source.
structural design
ae concept spec concept ae target specification
45HP air COOLED 2 x dyson digital brushless motor in hub outer motor casings structural battery weave chassis
3f 3r all 3psb
c
r n/p*d
e
f
d
1f 1r pinion transmission electric virtual lsd active torque vectoring traction 3d printed structural wiring loom in hub steering motors ecu governed virtual steering rack regen fr disc rear brakes
*
three second hold to park
a b
vw golf 7 for comparison 1:10 scale at 100 percent a..........wheelbase...........................................................................................................................................................3120mm b..........length............................................................................................................................................................4395mm c..........height............................................................................................................................................................1750mm d..........gvw............................................................................................................................................................
