Abstract
This research is intended to study the possibility of implementing low-cost Additive Manufacturing (AM) technologies to produce metallic automotive brake pedal rapidly, covering the main aspects of design, material, and manufacturing. The main objective of this research is to explore new brake pedal design considering AM design freedom, parts consolidation with reduced mass, new AM material and application of metal-based AM fabrication technology. The most widely used AM technology, the Fused Deposition Modelling (FDM), has been used to produce metallic brake using the metal-polymer filaments followed by debinding and sintering processes. Finite Element Analysis (FEA) has been applied to analyze the feasibility of new brake pedal design for AM processing. The prototype of the FDM produced metal brake pedal has been physically tested to validate the FEA results and to evaluate the reliability of metal based FDM technology.
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