The repairability of car body panels in a circular economy

Abstract

The current vision of Microcab is to increase the repair capabilities of the VIANOVA. Part of that vision is to begin the shift towards a circular economy in which the lifecycle of the product is extended, and parts can be processed in a circular manner during the lifecycle. Considering that Microcab is a small company and the challenge is considerable, additional safety regulations mean that a vehicle should become a road-safe vehicle. This graduation project contributes to this challenge by researching the main question that focusses on the front section of the vehicle: ‘How can Microcab design the front section of the VIANOVA to increase the repairability and solve the safety issues?’. Through several analyses and explorative design directions, the result is a concept that reconfigures the front section of the VIANOVA to allow for increased repairability and better safety requirements while maintaining the goal of becoming more circular. An important requirement is that the concept should allow for a production volume of 500 units annually. The current design of the front clip is a single large body panel hand-made from a glass fibre reinforced thermoset, which is difficult to repurpose and recycle. Based on research data, a sustainable alternative known as thermoplastic olefin (TPO) is introduced. Furthermore, the front clip has been split into four segments. These changes allow for better repair capabilities and lower the overall impact of a low-speed collision. In order to make this possible, structures were required to support the panels and increase energy absorption. The bonnet with incorporated headlights is enlarged to increase accessibility during service and fixated on the support structure, removing it from the impact zone. The support was required to improve safety for pedestrians and increase protection of internal components. This support consists of adding an energy absorber, upper load beams, cross member, and extending the width of the bumper beam. Additionally, it is recommended to use plastic fasteners to increase circular capabilities, considering that these are more likely to break, allowing for the body panels to remain intact. Lastly, it is recommended to implement a different type of surface finish. 3M provides an PVC-free wrap material, reducing the use of harmful chemicals and increasing repairability and circularity. This change also provides opportunities to illustrate internals or implement advertisement. Therefore, the project reveals that there are multiple elements that can have a positive influence on the repairability and safety issues while at the same time, shift towards a circular economy. The recommendations that emerged from the project provide a high desirability, but will require follow-up research am physical crash testing to determine optimal configuration of the front section, and create a better understanding of the elements and how they influence impact resistance and repairability.