Design criteria for thermo-plastic matrix composites (TPMC) and additive manufacturing of powertrain components

The design of powertrain system and components is constantly advancing towards a powerplant with higher specific power output while also increasing the overall efficiency, whether in stationary or unsteady regimes of operations. This constant advance is achieved while pursuing the goal of delivering to the final user of the vehicle a reduced fuel consumption as well as to meet ever more challenging emission regulations. This thesis discusses current internal combustion engine materials and manufacturing processes, both sophisticated and traditional and the main objective is to evaluate the use of composite materials, particularly the thermoplastic matrix composites to generate automotive powertrain components, assessing the possible use of additive manufacturing methods during its production. The bigger problem of the current manufacturing methods that are employed to produce components in thermoplastic matrix composite materials is the difficulty in escalating the production, due to its construction handmade methods are necessary, making it a slow and expensive process. The use of additive manufacturing methods for this type of composite materials could have the potential of reducing weight, costs, and production times whereas enhancing efficiency, performance, and durability of the powertrain.