Innovative solutions for automotive composite frames

High-pressure components usually require specialized restraint systems to handle dynamic loads and alignment precision in industrial applications. This thesis details the development of a mounting framework during my Tesla internship, focusing on prototypes for functional validation and for production-intent refinements. Key challenges included transient load management during pressurization, integration with equipment interfaces, and compatibility with in-house tested composite material configurations. Parametric 3D modeling (CATIA 3DX) and iterative finite element analysis (FEA) led to a hybrid design combining metallic straps, composite supports, and elastomeric interfaces. For the prototyping phase, assembly standardization (Design for Assembly principles) and time-sensitive manufacturing (VARTM composites, CNC machining, sheet metal) were prioritized. Future efforts will focus on process optimization for industrial deployment. Industrial refinements, indeed, target scalable production, exploring prepreg/autoclave composite layup, and potential aramid fiber straps, to balance cost, compliance, and performance.