Abstract: A part formed by an additive manufacturing process consist of regions of voids, regions of solid material, and regions of non-uniform lattice cells, where each lattice cell includes bars. The regions are spatially distributed throughout the part as a function of load conditions such that the solid material is distributed in regions of first load paths and the non-uniform lattice cells are distributed in regions of second load paths lower in magnitude than the first load paths. Diameters of each bar of a non-uniform lattice cell are sized as a function of at least one of a resolution unit of the additive manufacturing process and part performance requirements. The diameters of the bars of the non-uniform lattice cells are classified into clusters with an average diameter size being assigned to all non-uniform lattice cells in the same cluster.

Abstract: A part formed by an additive manufacturing process is provided, which consists of three (3) regions: regions of voids with no material; regions of solid material; and regions of non-uniform lattice cells. The regions are spatially distributed throughout the part as a function of load conditions such that the solid material is distributed in regions of first load paths and the lattice cells are distributed in regions of second load paths lower in magnitude than the first load paths. The lattice cells are tailored to the additive manufacturing process constraints and machine resolution.

Abstract: An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.

Abstract: A bumper assembly includes a bumper beam and a fin supported by the bumper beam. The fin extends along an axis from a proximate end proximate to the bumper beam to a distal end distal to the bumper beam. The fin has a sinuous cross section and a thickness each normal to the axis. The thickness at the distal end is less than the thickness at the proximate end.

Abstract: A bumper assembly includes a bumper beam and a fin supported by the bumper beam. The fin extends along an axis from a proximate end proximate to the bumper beam to a distal end distal to the bumper beam. The fin has a sinuous cross section and a thickness each normal to the axis. The thickness at the distal end is less than the thickness at the proximate end.

Abstract: An energy absorber including a cover defining a cavity and a lattice core. The lattice core includes rod-shaped links having first and second ends connected at spaced nodes to form a three-dimensional structure disposed inside the cavity. The lattice core includes a first portion and a second portion that has a higher density than the first portion. The second portion is arranged behind the first portion relative to an expected direction of an impact with an object that initially contacts the cover in front of the first portion. A third portion may be arranged behind the second portion relative to the expected direction of an impact that has a higher density than the second portion. The first core may be a three-dimensional body having a negative Poisson's Ratio. The lattice core may be formed by an additive printing process.

Abstract: A bumper assembly includes a bumper beam and a fin supported by the bumper beam. The fin has a proximate end proximate to the bumper beam and a distal end distal to the bumper beam and an axis extending from the proximate end to the distal end. The fin has a sinuous shape in a cross section normal to the axis.

Abstract: A bumper assembly includes a bumper beam and a fin supported by the bumper beam. The fin has a proximate end proximate to the bumper beam and a distal end distal to the bumper beam and an axis extending from the proximate end to the distal end. The fin has a sinuous shape in a cross section normal to the axis.

Abstract: A seatbelt anchor includes an attachment portion. The seatbelt anchor includes a seatbelt support portion spaced from the attachment portion to define a slot therebetween. The seatbelt anchor includes a pair of connecting portions spaced from each other with the slot disposed therebetween and connecting the attachment portion to the seatbelt support portion and including a lattice structure that is plastically deformable relative to the attachment portion and the seatbelt support portion.

Abstract: An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.

Abstract: A part formed by an additive manufacturing process is provided, which consists of three (3) regions: regions of voids with no material; regions of solid material; and regions of non-uniform lattice cells. The regions are spatially distributed throughout the part as a function of load conditions such that the solid material is distributed in regions of first load paths and the lattice cells are distributed in regions of second load paths lower in magnitude than the first load paths. The lattice cells are tailored to the additive manufacturing process constraints and machine resolution.

Abstract: A seatbelt anchor includes an attachment portion. The seatbelt anchor includes a seatbelt support portion spaced from the attachment portion to define a slot therebetween. The seatbelt anchor includes a pair of connecting portions spaced from each other with the slot disposed therebetween and connecting the attachment portion to the seatbelt support portion and including a lattice structure that is plastically deformable relative to the attachment portion and the seatbelt support portion.

Abstract: An energy absorber including a cover defining a cavity and a lattice core. The lattice core includes rod-shaped links having first and second ends connected at spaced nodes to form a three-dimensional structure disposed inside the cavity. The lattice core includes a first portion and a second portion that has a higher density than the first portion. The second portion is arranged behind the first portion relative to an expected direction of an impact with an object that initially contacts the cover in front of the first portion. A third portion may be arranged behind the second portion relative to the expected direction of an impact that has a higher density than the second portion. The first core may be a three-dimensional body having a negative Poisson's Ratio. The lattice core may be formed by an additive printing process.

Abstract: A seatbelt tongue includes a webbing-receiving portion, a tongue portion, and a connecting portion connecting the webbing-receiving portion and the tongue portion. The connecting portion includes a lattice structure plastically deformable relative to the webbing-receiving portion and the tongue portion.

Abstract: A vehicle an underbody structure includes a bumper, a subframe, and a frame. The frame interconnects the bumper and the subframe. The frame includes first and second symmetrical halves spaced at a distance. The frame is attached to the bumper at front segments of each of the halves, and to the subframe at rear segments of each of the halves. The halves are defined by a plurality of legs formed with the front and rear segments such that the first and second halves define load paths configured to transfer energy throughout the frame.

Abstract: A crush can to an automotive vehicle has a twelve-cornered cross section comprising sides and corners creating internal angles and external angles. A geometry of the cross section varies between a front section and a rear section of the crush can. The geometry of the cross section is optimized using a plurality of control parameters including a lateral width, a vertical width, a taper ratio, a front scaling factor, and a rear scaling factor.

Abstract: A method for optimizing a twelve-cornered strengthening member comprises: modeling a vehicle assembly including a strengthening member having a twelve-cornered cross section; parameterizing a geometry of the strengthening member with a plurality of control parameters; defining a design of experiment using the plurality of control parameters; modeling a vehicle using the vehicle assembly; simulating a frontal impact event with the vehicle; generating a response surface based on the frontal impact event; and determining a set of optimized control parameters for the strengthening member based on the response surface.

Abstract: A method for optimizing a twelve-cornered strengthening member comprises: modeling a vehicle assembly including a strengthening member having a twelve-cornered cross section; parameterizing a geometry of the strengthening member with a plurality of control parameters; defining a design of experiment using the plurality of control parameters; modeling a vehicle using the vehicle assembly; simulating a frontal impact event with the vehicle; generating a response surface based on the frontal impact event; and determining a set of optimized control parameters for the strengthening member based on the response surface.

Abstract: A three-piece tailor welded blank vehicle door structure includes a periphery defined by a bottom portion, a pair of opposing side portions, a top portion, and an inclined portion. A first thickness gage sheet material portion is disposed generally along the door hinge side of the door structure. A second thicker gage sheet material portion is disposed generally along the door latch side of the door structure. A thinner gage sheet material portion is disposed between the first and second thickness gage sheet material portions, whereby the overall weight of the vehicle door is reduced.

Abstract: A mounting structure 10 having improved stiffness characteristics. The mounting structure 10 includes a pillar 14 which forms a portion of a vehicle body 12 and which operatively supports a vehicle door which is selectively attached to the pillar 14 by hinges 16. The structure 10 includes a pair of “closed-loop” beads which are formed around hinges 16, and which increase the stiffness characteristics of the pillar 14 and of the vehicle door.