Toyota Console Box - Challenge

Toyota Motor Corporation (Toyota) wanted to launch the "LQ", a concept vehicle that leverages advanced technology to build an emotional bond between car and driver, at the Tokyo Motor Show. The next generation of the Toyota "Concept-i", a concept vehicle first exhibited at the 2017 Consumer Electronics Show, LQ would be equipped with automated driving capabilities and "Yui," a powerful artificial intelligence-powered interactive agent designed to learn from the driver and deliver a personalized mobility experience.

"In the past, our love for cars was built on their ability to take us to distant places and enable our adventures," said LQ development leader Daisuke Ido. "Advanced technology gives us the power to match customer lifestyles with new opportunities for excitement and engagement. With the LQ, we wanted to propose a vehicle that can deliver a personalized experience, meet each driver's unique mobility needs, and build an even stronger bond between car and driver."

A new approach was required for the interior and exterior design. The center console was designed as an innovative free-standing object with a knob style shift lever and a touch pad. This free standing design represented a major challenge. Additive design and manufacturing technology offered the best solution in terms of weight, design freedom, and reliability.

FIT provided consulting during the selection of the material and manufacturing technology, design assistance including stress analysis, and manufacturing of the center console in compliance with Toyota's standards and guidelines for automotive interior parts. The result was a reduction of the number of individual parts as well as a reduction of weight, and an overall exciting and new look of the console.

Toyota Console Box - Challenge
Toyota Console Box - FIT Solution

Toyota Console Box - FIT Solution

ADM-V (serial production of end-use parts)

Feasibility check
Result: Additive manufacturing of the console boxes considering the standards and guidelines for automotive interior parts is possible, but a complete redesign is necessary.

Feasibility study
- Recommended material: PA 2241 FR (after material tests within an ADM-D project)
- Recommended technology: Selective Laser Sintering (SLS)

ADM-E project
- AM-optimized lightweight redesign of the geometry and the inner structure of the console box on basis of the Toyota design guidelines (incl. FEA analysis)
- Reduction of the number of individual parts and thus of component complexity

AM optimization
Cutting the part into pieces for perfect nesting and heat-optimized positioning in the build chamber

AM validation
Result of the test production: Development and use of customized jigs for perfect welding and assembling

Additive manufacturing of 20 console boxes with our highly standardized AM process for Selective Laser Sintering (SLS) of end-use parts

- Blasting
- Assembling
- Welding of the individual parts

Quality assurance
- Visual inspection of all individual parts
- Measurement and control of tensile tests
- Numbering of all components and all test parts for full traceability

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