Design and Integrating Aerodynamic Analysis of Car Side Mirror and Manufacturing Through Fused Deposition Modeling

Abstract

The shifting automobile industry has resulted in important changes in the approaches and processes for producing a variety of products. As we move forward, the world is pivoting towards 3D printing, moving beyond traditional approaches. The production of a large number of new elements makes it difficult to uphold older designs and to create customized offerings with lower time and cost. The purpose of this research is to combine aerodynamic simulation with fused deposition modeling to improve the design and fabrication of automotive side mirrors and to increase their aerodynamic performance and structural integrity. This research aims at developing a hybrid conceptual model that integrates the simulation to enhance sustainable manufacturing breakthroughs within the automotive Industry. SolidWorks was used to develop the Models with the 0.02m, 0.04m, and 0.05m of width were examined to observe the overall increase and decrease of drag at 60 kph of velocity. 0.03m is the width of the conventional model, which is analyzed through Ansys Fluent Computational Fluid Dynamics (CFD) software. The findings of this research show that the combination of aerodynamic analysis with fused deposition modeling remarkably improves the design and function of automotive side mirrors, leading to better aerodynamic performance and 17 % less drag force on the optimized Model with a 0.02m width. The research demonstrates that advanced manufacturing methodologies hold the promise to enhance vehicle elements, creating a solid base for more environmentally friendly and efficient designs.