Design methods for mobility

Additive Manufacturing techniques enable the realization of complex and free-form geometries that are difficult to realize with traditional subtractive processes. These geometries can be useful in searching for a lightweight design of existing objects. One of the main tools to achieve lightweight parts is the use of lattice structures, where the bulk volume is replaced by a pattern of unit cells. This paper presents a method to lightweight a kart connecting rod using lattice structures, with the idea of realizing this connecting rod with the L-PBF technique.

Keywords: Connecting Rod , Design for Additive Manufacturing , Kart , Lattice Structures , Lightweight Design

The increasing interest in foiling sailing yachts, recently driven by the American's Cup, led to a wider application even in small boats such as dinghies or windsurfing. Foiling seems to be recent but since the early twenty-century years, hydrofoils has been experimented in Italy. This paper shows the complete foil design process starting from classical wing design based on theoretical consideration and illustrating the importance of modern simulation environments in design processes. Commercial CFD code Ansys Fluent® has been used and the results have been compared with those obtained through ad hoc developed vortice lattex method software, showing a substantial agreement with RANS simulation and theoretical calculation in front of incredible time reduction for simulation process that would allow a numerical planform optimization in a reasonable time.

Keywords: CFD , Foiling , Yacht design

Tread geometry is one of the parameters that influence wear. Hence, investigating tread geometries and their evolution during tire usage becomes crucial for mitigating wear-related emissions. Among the state-of-the-art measurement methods, 3D scanning is notable for its ability to provide detailed insights into tread geometry. This study introduces a methodology for analysing the evolution of tire tread geometry, aiming to improve tire wear analysis. The proposed approach based on first derivative analysis and discrete data binning, was tested exploiting a benchmark tire generated virtually in a CAD software and sampling a point cloud on its surface, resembling 3D scanning acquisition. The results show its capability of leveraging 3D scanning technology to provide detailed insights into tread geometry by isolating sampled points located within grooves from those belonging to the outermost surface. The recognition of geometric features allows for the separate analysis of the different layers, extending the capability of average profile-based wear assessments to complex tread patterns, such as directional tires.

Keywords: Tire 3D scanning , Tire wear , Tread geometry evolution

owing tank tests are useful for evaluating the performance of hulls. One limitation of these tests is that large hulls cannot be tested at a 1:1 scale. However, although the tests are conducted on scaled models, the results can be scaled using ITTC (International Towing Tank Conference) procedures to provide a prediction of the full-scale model behaviour. Full-scale models, on the other hand, can be directly tested using CFD (Computational Fluid Dynamics) simulations, which do not have size limitations. In the present study, an ACS (Air Cavity Ship) hull model was tested in a 1:6 scale in a towing tank with and without air injection, with the full-scale results being derived from these tests. A towing tank scale and a full-scale CFD model were created in Simcenter Star-CCM +.

Keywords: ACS , CFD , Towing Tank

The issue of resistance reduction through hull ventilation is of particular interest in contemporary research. This paper presents multiphase computational fluid dynamics (CFD) simulations with 2-DOF motion of a planing hull. The original hull was modified by introducing a step to allow air ventilation. Following an assessment of the hull performance, a simulation campaign in calm water was conducted to characterize the hull at various forward speeds and air insufflation rates for a defined single step geometry. Geometric analysis of the air layer thickness beneath the hull for each simulated condition was performed using a novel method for visualizing local air thickness. Additionally, two new parameters were introduced to understand the influence of spray rails on the air volume beneath the hull and to indicate the primary direction of ventilated air escape. A validation campaign and an assessment of uncertainty of the simulation has been conducted. The features offered by the CFD methodology include the evaluation of the air layer thickness as a function of hull velocity and injection flow rate and the air volume distribution beneath the hull. The air injection velocity can be adjusted across various operating conditions, thereby preventing performance or efficiency loss during navigation. Based on these findings, the study highlights the benefits of air insufflation in reducing hull resistance for high-speed planing vessels.

Keywords: Air cavity ships , Computational fluid dynamics , Hydrodynamics , Maritime sustainability , Planing hull

Nowadays, modern vehicles comprise a vast number of components made from various materials and manufactured using different techniques, making the management of assemblability, functionality, and cost highly complex. This complexity necessitates controlling geometrical and dimensional deviations to meet product and process demands. Dimensional Management (DM), supported by standards such as ASME-GD&T and ISO-GPS, is increasingly employed for geometrical specification and tolerance analysis. Through Computer-Aided Tolerancing (CAT) tools, tolerances can be considered early in the design process using Design for Tolerancing (DfT) approaches. This study aims to develop and define a methodology for geometric specification allocation and tolerance stack-up analysis of automotive components. The methodology integrates predictive models, DM, and DfT approaches via computer-aided tolerance specification and analysis, enabling comprehensive modeling and simulation of tolerance effects on performance, quality, and assemblability.

Keywords: Geometric Dimensioning and Tolerancing , Geometrical Product Specification , Model Based Definition , Tolerance design

Conventional ground-based transport systems often experience delays due to congested traffic. This is unacceptable in the case of transporting organs, blood, medicines and emergency supplies, when time is critical. Urban Air Mobility (UAM) offers a solution to overcome transportation inefficiencies. In fact, Unmanned Aerial Systems (UAS) can quickly reach remote locations providing critical care in a timely manner. However, ensuring efficiency, safety and compliance with regulations is essential. This paper presents the mission-oriented design approach of a UAS, focusing on two subsystems, namely the Unmanned Aircraft (UA) and the Functional Container (FC). The design of the UA involves choices for configuring its layout. The FC design focuses on the preservation of the transported material. Lightweight and reliable dedicated solutions are designed for FC leveraging Additive Manufacturing (AM) technology. The design is mission-oriented, but allows systems to be reconfigured for additional missions.

Keywords: Advanced air mobility , Drone , medical , mission-oriented design , Unmanned air vehicle

Recently, most research efforts and resourced in Aeronautics are devoted to the development of Advanced Air Mobility (AAM) technologies. This term refers to all air mobility services based on autonomy and electrification of air systems and their infrastructure and when conducted in urban contexts is known as Urban Air Mobility (UAM). However, the integration of these systems and what is their environmental, social and economic impact is still unknown and such ignorance may decelerate its effective implementation and thus enjoyment of the benefits. In this context, visualization and interaction technologies such as Extended Reality Technologies (XR) can be leveraged as enabling technologies aiding in the deployment of AAM and UAM. In this paper, we present an overview of methodologies for designing human-machine interfaces in aeronautics and the results of a study of tools and methods for prototyping virtual urban environments for XR-UAM applications.

Keywords: Human Machine Interfaces , UAM - Urban Air Mobility , XR – Extended Reality

The digital modeling and optimization of production processes in the aerospace sector are crucial endeavor for enhancing operational efficiency and competitiveness. This paper presents the process optimization strategy of an aerospace production line by adopting the discrete event simulation technique. The 3DExperience platform has been chosen as a promising co-simulation tool for the digital model development. The production processes have been digitally modeled, and process flows have been analyzed for achieving a comprehensive line flow balancing optimization identifying critical bottlenecks. Various scenarios have been analyzed and compared enhancing process operational efficiency. Initial results outline significant imbalances in the utilization of workstations, suggesting a lack of efficiency in resource allocation.

Keywords: Aeronautical Components , Assembly Line , Line Flow Balancing , Process Optimization

Despite the European Union's efforts to decrease workplace accidents, statistics show an increase in accidents in the last years. Therefore, training workers is crucial to prevent injuries. The thriving of new technologies, such as Immersive Virtual Reality, can offer innovative training methods in the industrial field. However, introducing innovative technologies to a user base with an increasing average age necessitates evaluating the impact on workers across various age groups. In this contribution, we developed an IVR system to train workers to learn procedures in industrial environments. We recruited 50 participants and divided them into three age groups: young (19–33 years), middle-aged (34–48 years), and older (49–63 years). Objective (execution errors and times) and subjective metrics (User Experience Questionnaire (UEQ), System Usability Scale (SUS), and Virtual Reality Sickness Questionnaire (VRSQ)) were collected. The results showed that the young group made more mistakes than the other two groups, but there were no statistically significant differences in execution times. The SUS score was statistically significantly higher for the young group than the others, the VRSQ did not show any significant increase.

Keywords: Age-related Performance , Immersive Virtual Reality (IVR) , Industrial Safety Training , User Experience Metrics , Workplace Accident Prevention

The industrial revolutions driven by Industry 4.0 and 5.0 are transforming work practices with new tools like Augmented Reality (AR), which promise to boost productivity in industrial settings. This study introduces an AR application for the HoloLens 2 to evaluate three interaction metaphors - hand-ray, near, and gaze interaction - for moving virtual objects, focusing on accuracy and ergonomics. ErgoSentinel software provided real-time ergonomic analysis through RULA scores, and the NASA-TLX questionnaire assessed perceived workload. Results indicate that ray interaction is the most ergonomically favorable for long-distance tasks, reducing physical strain and enhancing comfort. Near interaction is precise for short-distance tasks but increases physical strain over long distances. Gaze interaction balances physical strain reduction with potential precision loss in long-distance tasks, imposing a higher cognitive load.

Keywords: Augmented Reality , Ergonomics , Industry 5.0 , RULA

Modern design products are increasingly complex and emotionally significant, demanding versatile and collaborative customization. However, a literature and commercial review reveals a limited availability of flexible, multi-user, photorealistic Virtual Reality (VR) systems for product configuration. We introduce MAGIC (Multi-user Advanced Graphic Immersive Configurator), a collaborative platform combining realistic graphics with ergonomic validation using digital avatars, addressing the limitations of 2D visualization and existing tools. MAGIC is evaluated in a yacht design case study involving 30 participants in an immersive, co-located configuration of a sailing yacht to assess the system's usability and the potential of VR for customizing complex products. Results show MAGIC's feasibility in supporting multi-user configuration (100% success rate) and achieving a strong usability score (SUS = 80.83). User feedback highlights that high-quality graphics and additional content significantly enhance immersion and user engagement. However, encountered challenges with navigation methods and spatial perception indicate areas for improvement. MAGIC's collaborative and immersive capabilities can be extended to other industries demanding proactive customer engagement in the customization of large, heavy products and ergonomic design.

Keywords: collaboration , marine industry , multi-user , product configuration , virtual reality , yacht design

Marine microplastic pollution has emerged as a pressing environmental issue, with significant implications for aquatic ecosystems, human health and global biodiversity. Ports, acting as semi-enclosed environments, are critical zones where plastic waste, including microplastics, plastic fragments smaller than 5 mm, tend to accumulate. These settings provide controlled conditions that are ideal for deploying innovative solutions to monitor and mitigate the impact of microplastic pollution. This paper presents the design, development and initial testing of an autonomous surface drone engineered specifically to monitor and collect microplastics in port environments. Unlike traditional marine drones, this device operates exclusively at the water surface, leveraging mechanical filtration systems to capture and quantify microplastic fragments. Designed for cost-efficiency, ease of manufacturing and operational simplicity, this drone aligns with principles of environmental sustainability and scalability.

Keywords: autonomous drone design , design for disassembly , eco-compatible engineering , marine environmental monitoring , microplastic filtration

Virtual reality (VR) technologies have shown significant potential in enhancing the automotive design process by providing immersive, interactive, and collaborative environments for reviewing complex vehicle architectures. Traditional CAD models and physical prototypes often struggle to offer the flexibility needed for rapid iteration and spatial understanding, especially for systems such as hydrogen-powered commercial vehicles. This study aims to develop a VR platform to improve the collaborative review of the internal architecture of a hydrogen-powered commercial vehicle, specifically focusing on the spatial arrangement and interaction of critical components such as hydrogen tanks, fuel cells, and batteries. The goal is to enhance design processes, reduce iteration costs, and improve spatial understanding and decision-making within automotive teams. The VR environment was built using Unity 3D and optimized for mobile VR platforms, incorporating features such as interactive component manipulation, dual locomotion modes (teleportation and free movement), and real-time collaboration. The platform was tested with a range of users, including automotive professionals and students, to evaluate its usability, performance, and impact on spatial understanding and user engagement. User feedback demonstrated high levels of satisfaction, with 85% of participants reporting improved spatial understanding, 80% preferring VR over traditional CAD tools, and 90% noting increased engagement. The VR platform enabled faster completion of assembly tasks (40% faster than traditional methods) and improved collaborative decision-making. However, challenges such as system performance issues, motion sickness, and a steep learning curve were reported by some users, particularly nontechnical users. The VR platform developed in this study significantly advanced the collaborative and immersive review of automotive designs, offering tangible benefits in terms of engagement, spatial comprehension, and design iteration efficiency. While there were limitations related to hardware requirements and user accessibility, the results highlight the transformative potential of VR in automotive design and education.

This paper presents an integrated approach that combines Industrial Design Structure (IDeS) methodology with Human-Centered techniques to optimize the safety and comfort of hybrid sports vehicles. The study begins with an in-depth analysis of styling trends and then moves on to custom 2D and 3D modeling. A unique method employing calibrated dummies allows customization of the dimensions of the passenger compartment, prioritizing ergonomic features. It has been observed that this approach improves vehicle aesthetics and ensures optimal ergonomic design while prioritizing occupant safety and comfort.

Keywords: Car Design , Ergonomics , Human-Centered Design

The Modena Automotive Smart Area (MASA) is an experimental project, based on a public-private partnership, aiming at the development of an urban living lab to test, evaluate, and implement connected and autonomous vehicles. It is proposed as a case study that contains all the key elements to convey scalability, replicability, and operational flexibility. MASA is an example of public-private partnership with the Municipality of Modena and the University of Modena and Reggio Emilia, strengthened by the endorsement of the Italian Ministry of Infrastructures and Transport and the support of the Emilia-Romagna Region, also involving industrial partners, in the implementation of a triple helix model. The research and experimentation activities concern interactions between vehicles, between vehicle and moving obstacle, between vehicle and city.

Keywords: Autonomous driving , Living Lab , Smart City

Pneumatically-driven Soft Growing Robots (SGR) are a new class of continuum robots, which take inspiration from vines, mimicking their capability to evolve along a path from the tip, while being intrinsically safe towards the environment. The SGRs' capabilities can be empowered by providing them with the capability to mount sensors and tools at the tip, thus enabling many applications in unstructured environments, such as object transportation in constrained spaces. However, the tip position of SGRs changes over time during growth, making it challenging to keep tools attached at the tip in the desired configuration. An auxiliary device at the tip is required, which grows with the SGR without hindering the eversion or changing the robot's designed shape. In this work, currently implemented designs in the literature for enabling SGRs tip-attachment are analyzed. Then, a novel tip-mounted Hybrid Magnetic Cap (HMC), composed of textile and rigid components, is presented; this dual nature makes the device both safe and efficient during all the SGR operative phases. To prove its effectiveness, this design is applied to a specific case study: cable delivery along a straight path.

Keywords: Bio-inspired design , Object delivery , Pneumatic actuation , Soft Robotics

The increasing demand for lightweight automotive frames is pushing toward adopting composite materials and automating the related manufacturing and assembly processes. Carbon Fiber Sheet Molding Compounds, CF-SMC, enable custom-shaped car body parts fabrication through a single-step compression molding process. Nevertheless, conventional manual stack-up impacts productivity since it is the operation required to enable the compression molding. Robotic manipulation of the pre-shaped uncured composite stacks can relax the continuity between these two phases. The handling process requires dedicated grippers to keep the deformable composite stacks within the shape deviations required to fit on the compression mold. To this aim, a two-stage integrated approach to design the robotic grippers is presented in this work. Bounded by the maximum allowed deformation to fit the mold, the first stage returns the grasping pattern, that is the optimal grasp point map. The second stage aims to identify the lightest stiffer frame for the gripper. A Computer-Aided Design platform is adopted to integrate the two phases of the method.

Keywords: CAD Platform , CS-SMC , Integrated design , Robotic Grippers

The MUNER Association is finalized to carry out innovative teaching-by-learning methodologies in a multidisciplinary approach. Based on this framework, it offers three inter-universities Master's Degree programs on the Automotive theme, with the aim of attracting international talent and training them on extremely specialized topics. These programs were pioneers in the adoption of teaching methods characterized by a strong contamination of the academic world with the industry realities, by a strong interdisciplinary approach, especially on the themes that characterized the technological innovation in the automotive sector.

Keywords: Competence gap , Education , Motorvehicle Industry

The large availability of low-cost, mass-produced drones has shaken the economic and production capabilities of most intermediate-range missile (IRM) systems. IRMs are capable of taking out mortars, rockets, unmanned aerial vehicles (UAVs) and missiles from 4 to 100km with a unitary cost of the "killer"unit of five figures. The preliminary design of these UAVs may benefit from existing jet models. This study evaluates the cost-effectiveness of these unmanned aerial vehicle interceptors (UAVIs) that can replace the IRMs with reusable small UAVs with booster rockets.

Keywords: Anti-missile systems , cost-effective , re-usable , UAV