Alternative Selection Material and Auto Part Manufacturing Process for Fused Deposition Modeling Using CAD-CAM-CAE Tools

The automotive industry seeks to select suitable alterna tive materials for manufacturing curtain air intake through additive manufacturing with FDM fused material deposition technology. First, it obtains the geometry with exact dimensions and details through re verse engineering techniques with a 3D scanner, generating a CAD post processing. For the material selection, has been used using finite element analysis FEM by HyperWorks software simulating the mechanical behav ior with the original PP - EPDM material, two materials are selected to be validated for manufacturing in 3D Printing, Kevlar-ABS filament and PTEG, with a maximum displacement of 8,97mm PP - EPDM, 10,47mm Kevlar-ABS, 8,37mm PTEG and maximum stress of 9.804e4 kPa PP - EPDM and Kevlar-ABS 1.00e5 kPa. The results allow the experimen tal factorial design for the 3D Printing as a sandwich-type composite material with the following order of layers (Kevlar-ABS) + PTEG + (Kevlar-ABS). These are the basic parameters for the test pieces manu factured for tensile and flexural strength tests, with two variables to be evaluated: infill and percentage of matrix and reinforcement material. With this methodology, it is possible to reduce uncertainty when select ing new materials for an alternative manufacturing process, showing the advantage of using Kevlar-ABS and PTEG fiber as lightweight materials for weight reduction.