Abstract
Continuous carbon fibre reinforced plastics (CFRP) are attractive lightweight materials for automotive applications due to their high specific strength and stiffness. Recent advances in additive manufacturing enable improved structural performance through controlled continuous fibre path design. This study proposes an integrated design methodology combining ABAQUS–Python coupled topology optimization with G-code based continuous fibre path reconstruction to reduce the weight of a control lower arm. A cyclic multi load topology optimization framework was developed considering four representative loading conditions: pothole braking, reverse braking, outer cornering, and inner cornering. The method of moving asymptotes was employed to obtain the optimal material layout. Fibre paths were extracted from manufacturing G-code and reverse modelled into an ABAQUS finite element model using the embedded element method to represent interactions between the PETG matrix and carbon fibres. The results demonstrate feasibility for practical automotive structural applications.
| Translated title of the contribution | Integrated Design Method of Lightweight CFRP Lower Control Arms Using ABAQUS–Python Coupled Topology Optimization and Reconstruction of Continuous Fibre Paths |
|---|---|
| Original language | Korean |
| Pages (from-to) | 211-221 |
| Number of pages | 11 |
| Journal | Transactions of the Korean Society of Mechanical Engineers, A |
| Volume | 50 |
| Issue number | 3 |
| DOIs | |
| State | Published - 2026 |
Keywords
- Additive Manufacturing
- Continuous Carbon Fibre Reinforced Plastic
- Lower Control Arm
- Topology Optimization
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