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Arcimoto and XponentialWorks lightweight Fun Utility Vehicle using DfAM

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Corporate advisory company XponentialWorks, which specializes in 3D printing, AI and other next-gen technologies, is turning its focus to the road through a new partnership with electric vehicle company Arcimoto. Together, the companies are producing lightweight 3D printed components for Arcimoto’s Fun Utility Vehicle (FUV) with the aim of reducing costs and improving performance, efficiency and environmental friendliness.

The joint project, which leverages 3D printing as well as ParaMatters’ unique generative design software, CogniCAD, will explore the potential of using DfAM to lightweight parts for Arcimoto’s FUV. If the project proves to be a success, the electric vehicle company will consider integrating more lightweighted components to replace traditionally manufactured parts in its electric vehicles. Decreasing the overall weight of its vehicles will lead to better battery efficiency (traveling more miles on a single charge), as well as better acceleration and handling.

Arcimoto XponentialWorks Fun Utility Vehicle

Using ParaMatters’ CogniCAD software (which you can read about in more depth here), Arcimoto and XponentialWorks tackled the redesign of four main components: a rear swing arm, knuckle, upper control arm and brake pedal. In all cases, significant weight reductions were achieved.

  • The rear swing arm saw a weight reduction of 34% compared to the original part
  • The knuckle saw a weight reduction of 36% compared to the original part
  • The upper control arm saw a weight reduction of 52% compared to the original part
  • And the brake pedal saw a weight reduction of 49% compared to the original part

Arcimoto XponentialWorks Fun Utility Vehicle

The weight reductions were achieved thanks to the software’s ability to generate nature-inspired geometries, which reduce material use and weight without sacrificing structural integrity and strength. CogniCAD is an AI-powered platform that generates part geometries based on design goals and material parameters. The software also enables users to benefit from part consolidation, which can help reduce assembly weight even more.

“We are very excited to work with Arcimoto to leverage our technological know-how to make this incredible vehicle even more outstanding,” said XponentialWorks Founder Avi Reichental. “The entire redesign, from concept to parts, took only four weeks, further demonstrating how 3D printing technology is completely changing how we design and manufacture products.”

Arcimoto XponentialWorks Fun Utility Vehicle

Arcimoto XponentialWorks Fun Utility Vehicle

Mark Frohnmayer, Arcimoto CEO, added: “We are thrilled to open Arcimoto’s ultra-efficient vehicle platform to XponentialWorks’ team of lightweighting and additive manufacturing experts. Our mission to rightsize the footprint of daily mobility means a continued commitment to optimizing not just the vehicle platform architecture, but all of its constituent parts as well. The speed at which the XponentialWorks team has made meaningful weight improvements to core components of the Fun Utility Vehicle is truly impressive.”

“In this new age of industry 4.0 manufacturing, no one company can do it all alone,” Reichental concluded. “This project demonstrates the power of curating relationships and building joint innovation programs that pool together resources and expertise from complementary organizations to create practical tractable products in record time.” 

Arcimoto’s FUV is currently being showcased at Tech Hub at the Beverly Hilton Hotel in California.

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Tess Boissonneault

Tess Boissonneault is a Montreal-based content writer and editor with five years of experience covering the additive manufacturing world. She has a particular interest in amplifying the voices of women working within the industry and is an avid follower of the ever-evolving AM sector. Tess holds a master's degree in Media Studies from the University of Amsterdam.

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