BEng Project

Design and manufacturing of a bioinspired adaptive structure with enhanced damage tolerance

Project Overview:

This project focused on the design and manufacture of a bioinspired shape-morphing car spoiler. The inspiration came from dragonfly wings, which use a mechanical system of vein joints to achieve controlled shape changes. Unlike birds, whose wings change shape due to muscles, dragonfly wings lack muscles and rely solely on these vein joints to adapt under different aerodynamic forces. This made them an ideal model for designing a spoiler capable of morphing its shape without the complexity or weight of traditional active mechanisms. The resulting design offers enhanced vehicle stability, control, and reduced drag, leading to more efficient performance.

Project Objectives:

• Design, prototype, and test a bioinspired car spoiler that could morph its shape based on wind conditions. 

• Develop a lightweight and efficient mechanism to control the deformation and optimise downforce. 

• Test the spoiler’s performance to ensure it adapts to different wind speeds while minimising drag and improving overall vehicle efficiency.

Research and Concept Development:

The concept was based on biomimicry, specifically studying the joints and structure of dragonfly wings, which allow controlled deformation under different forces. Various insect wing structures were examined under microscopes to understand how they function. Research was focused on adapting these natural mechanisms into a car spoiler that could adjust its shape without the complexity and weight of traditional active systems.

Design and Prototyping:

Prototyping involved the 3D printing of joints inspired by dragonfly wings and implementing them into a lamination sheet for controlled deformation. Multiple versions of joints were tested to determine the best design for achieving shape morphing. A spoiler prototype was then created using this design, with a mechanism for adjusting deformation via thread pulling, allowing the spoiler to change its shape in response to wind conditions.

Testing and Analysis:

Tests were conducted to measure the deformation and aerodynamic performance of the spoiler at different angles and wind speeds. The bioinspired spoiler showed improved downforce control compared to traditional fixed spoilers. The final testing setup also included static tests to measure the force and displacement required to morph the spoiler, confirming its efficiency at various angles of attack.

Key Outcomes:

• The bioinspired spoiler outperformed conventional spoilers in terms of adaptiveness and aerodynamics, offering better vehicle stability at high speeds.

• The final design was lighter and simpler than current active spoiler designs, achieving the aim of reducing unnecessary drag while improving downforce.

• Shape morphing mechanism proved to be highly effective for controlling aerodynamic forces.

Learning and Future Applications:

This project demonstrated the potential of biomimicry in automotive design, especially in creating more efficient, adaptable structures. Future applications could extend beyond automotive spoilers, including aerospace components and wind turbine blades. Further research could explore using different materials to enhance performance and conducting more real-world tests in wind tunnels or simulations.