SMART-LATTICE
Decarbonization
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Involved partners
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Polytechnic University of the Marche University of Brescia Polytechnic University of Bari University of Pisa Fiat Research Center S.C.P.
Lightweight and crashworthy Lattice Structures in Fe-Based Shape Memory alloys by PBF-LB for Automotive Safety Applications
The SMART-Lattice project explored the potential of 3D printed metallic lattices to create safer, lighter, and more sustainable automotive components. By combining advanced steels (17-4PH) and Fe-Mn-Si shape memory alloys with innovative lattice architectures, the project developed and tested crash absorbers capable of reducing vehicle weight while improving energy absorption.
Using additive manufacturing based on the Laser Beam Powder Bed Fusion technique, researchers optimized process parameters to ensure defect-free production, high-quality components, and superior mechanical properties. Parametric design, along with non-destructive testing techniques, allowed for precise control of lattice geometry, achieving superior mechanical behavior, while numerical simulations efficiently predicted the compressive response.
A key demonstration involved redesigning the front crash box of the Jeep Renegade, with prototypes able to meet stringent energy absorption requirements and a weight reduction of up to 30%. Beyond automotive safety, the project highlights the environmental benefits of additive manufacturing, including material efficiency, recyclability, and reduced emissions. By linking advanced research and industrial application, SMART-Lattice enhances European competitiveness in advanced manufacturing and sustainable mobility.
