Abstract: A vehicle module system is disclosed. The system includes a track assembly operably coupled with a body of a vehicle. One or more modules may be removably and slidably coupled with the track assembly. The modules include base structure defining an attachment point. A rail feature is disposed along a bottom portion of the base structure. An attachment feature having a retainer for removably coupling to the attachment point to the base structure.

Abstract: A vehicle door includes a trim panel coupled to a frame. A single-piece armrest substrate is coupled with the frame. The armrest substrate is a three-dimensionally printed member having interior walls that are printed within the armrest substrate according to a virtual force model generated during a virtual impact scenario. The interior walls define a plurality of voids defined within the armrest substrate.

Abstract: A method of manufacturing a component with at least one embedded feature includes the steps of defining a boundary template for the component, reserving a functional region within the boundary template for the at least one embedded feature, consolidating and structurally optimizing the component to allow more efficient distribution of material and manufacturing the component using additive manufacturing techniques. A motor vehicle component including a motor vehicle center console are also disclosed.

Abstract: A vehicle module system is disclosed. The system includes a track assembly operably coupled with a body of a vehicle. One or more modules may be removably and slidably coupled with the track assembly. The modules include base structure defining an attachment point. A rail feature is disposed along a bottom portion of the base structure. An attachment feature having a retainer for removably coupling to the attachment point to the base structure.

Abstract: A computer system generates a lattice structure effective to satisfy static loading criteria, the lattice structure including surfaces, nodes, and branches interconnecting nodes. The branches are removed and various alternative configurations are tested to identify one that meets low frequency damping requirements. An outer damping layer is selected to satisfy high frequency damping requirements and is added to the lattice structure. The lattice structure may then be fabricated using an additive manufacturing device.

Abstract: A vehicle door includes a trim panel coupled to a frame. A single-piece armrest substrate is coupled with the frame. The armrest substrate is a three-dimensionally printed member having interior walls that are printed within the armrest substrate according to a virtual force model generated during a virtual impact scenario. The interior walls define a plurality of voids defined within the armrest substrate.

Abstract: A method of 3D printing a part with an overhanging portion requiring support during printing is provided. The method includes moving a dynamically adjustable support member to support the overhanging portion during printing of the part. The dynamically adjustable support member may be moved from a retracted position to a support position after a first portion of the part is printed and the overhanging portion may be supported by the dynamically adjustable support member in the support position. The part may be printed in a 3D printing chamber with a base and at least one wall. The base may have a first dynamically adjustable support member and the at least one wall may have a second dynamically adjustable support member. A first overhanging portion and a second overhanging portion of the part may be printed over the first dynamically adjustable support member the second dynamically adjustable support member, respectively.

Abstract: A vehicle module system is disclosed. The system includes a track assembly operably coupled with a body of a vehicle. One or more modules may be removably and slidably coupled with the track assembly. The modules include base structure defining an attachment point. A rail feature is disposed along a bottom portion of the base structure. An attachment feature having a retainer for removably coupling to the attachment point to the base structure.

Abstract: An assembly includes a series of support structures. Each of the support structures includes a base, a top plate having a continuous surface area, and a connector coupling the base to the top plate. The connector assumes a compressed position when under load from an object. The support structures that are in an extended position provide a lateral retention force to the object.

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 method of manufacturing a component with at least one embedded feature includes the steps of defining a boundary template for the component, reserving a functional region within the boundary template for the at least one embedded feature, consolidating and structurally optimizing the component to allow more efficient distribution of material and manufacturing the component using additive manufacturing techniques. A motor vehicle component including a motor vehicle center console are also disclosed.

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 console assembly includes a frame, having a plurality of module receivers, a plurality of modules held in the plurality of module receivers and a securing feature. The securing feature secures the plurality of modules in the plurality of modules receivers. A console assembly system allowing for the construction of a customized console assembly is also disclosed as is a related method of producing a console assembly.

Abstract: A computer system generates a lattice structure effective to satisfy static loading criteria, the lattice structure including surfaces, nodes, and branches interconnecting nodes. The branches are removed and various alternative configurations are tested to identify one that meets low frequency damping requirements. An outer damping layer is selected to satisfy high frequency damping requirements and is added to the lattice structure. The lattice structure may then be fabricated using an additive manufacturing device.