Optimum design of vehicle brake pedal from polymer composite material for additive manufacturing method and production as serial part replacement

3D printer and tape laying systems (commonly known as additive manufacturing systems) that produce parts from polymer composite materials are developing rapidly. However, production speeds are still low. At the moment, it is efficient to use for low volume production. In order to benefit from this feature of the device, the metal part used in mass production must be designed in accordance with additive production and the material and writing system of the composite 3D printer. In this study, it is about the production of the foot brake pedal which is still used instead of the hand brake in upper segment passenger and commercial vehicles, from polymer composite part as a substitute for steel, by the additive production method and experimentally examining the suitability of the steel part with the desired properties. The aim of the thesis is to make the optimum design of polymer composite 3d printers in accordance with the part printing strategies in order to provide the desired mechanical and physical properties of the part, to examine the suitability of the mechanical performance of the design with Finite Element Analysis and to test the suitability of the final performance with the 3d printer to the requirements expected from the real part by the vehicle manufacturer.