Proceedings of the
9th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN2022)
15 – 18 November 2022, Singapore

Additive Manufacturing Technology with Topology Optimization for Automobile Parts

Jeongho Yang1,5, Youngsuk Jung2, Jaewoong Jung3, Jae Dong Ock4, Shinhu Cho2, Sang Hu Park5, Tae Hee Lee3 and Jiyong Park1,a

1Advanced Joining & Additive Manufacturing R&D Group, Korea Institute of Industrial Technology, Incheon, 21999, Korea

2Advanced Materials Research Team, Hyundai Motor Group, Uiwang-si, Gyeonggi-do, Republic of Korea

3Premium Vehicle R&D Center, Korea Automotive Technology Institute, Yeonam-gun, Jeollanam-do, 58463, Korea

4Woosin industries corporation, Gimhae-si Gyungnam, 50877, Korea

5School of Mechanical Engineering, Pusan National University, Busan, 46241, Korea


We present a topology optimization of brake caliper for additive manufacturing, which is one of the most necessary automobile parts to reduce weight. The finite element analysis was performed to evaluate the mechanical properties on brake caliper parts. The topology optimization of brake caliper to which Ti-6Al-4V is applied has a higher safety ratio compared to the yield strength than the reference brake caliper. The precise shape of a brake caliper was manufactured using laser powder bed fusion (LPBF). Subsequently, heat treatment under the solution treatment condition decreased the yield strength due to increase machinability and ductility. The performance was evaluated by the JASO C406 test after post-processing and accessory assembly completed. The performance was similar to that of a commercial brake caliper, and it showed the possibility of using it as a product.

Keywords: Brake caliper, Additive manufacturing, Powder bed fusion (PBF), Topology optimization, Lightweight.

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