Innovation in solar vehicles: From concept to prototype in less than 24 months

• Published in: IOP conference series. Materials Science and Engineering 2019-10, Vol.659 (1), p.12086
• Main Authors: Maglio, S, Lukovic, M, Zavatta, N, Leardini, A
• Format: Article
• Language: English
• Subjects: Computational fluid dynamics; Concurrent engineering; Functional testing; Manufacturing; Multiple objective analysis; Optimization; Rapid prototyping; Solar energy; Three dimensional models
• ISSN: 1757-8981; 1757-899X
• DOI: 10.1088/1757-899X/659/1/012086

The present article describes the integrated path used for the conceptual, functional and constructive design of an exclusive multi-occupant solar-powered vehicle. The project was based on the massive implementation of concurrent engineering and quality tools, rarely used in such an integrated way, featuring a novel and attractive design, 3D CAD modelling, structural and fluid dynamics validations, in-scale rapid prototyping, functional tests, multi-objective optimization, parts manufacturing and assembly. Thanks to this approach, the solar car prototype presented high technological contents, especially in terms of materials, structures and processes. Furthermore, large CNC-machined multi-material molds and hybrid manufacturing solutions were adopted to speed up the production phase allowing to move from the initial concept to the final prototype within 24 months. Since June 2018, the solar vehicle is on the road transporting 4 people, weighing less than 300kg, reaching speeds of 120km/h and able to travel hundreds of kilometers with zero-emission and no fuel consumption.