Fabricación de un Prototipo de la Visera Superior del Faro de la Motocicleta “Pulsar Bajaj NS200” a partir del Rediseño y Fabricación Aditiva con Material Alternativo P-Glass/ABS.

Abstract

This research analyzes the mechanical behavior of the Bajaj Pulsar NS200 motorcycle headlight by manufacturing its visor with an alternative P-GLASS/ABS material using 3D printing additive manufacturing technology and computational validation through finite element analysis (FEA). The study is based on the need to evaluate the technical feasibility of alternative composite materials in automotive applications, considering criteria such as structural strength, deformation, impact, and thermal response. The P-GLASS/ABS filament was selected for combining the translucency and aesthetic properties of P-Glass with the toughness and mechanical durability of ABS, allowing for the production of functional components with a suitable surface finish and potential application in automotive parts. The methodology included the preliminary mechanical characterization of the material through tensile, flexural, compressive, and impact tests, complemented by three-dimensional modeling of the headlight in a CAD environment (Autodesk Inventor) and structural simulation in Altair SimLab. Parameters such as Von Mises equivalent stress, total deformation, and stress distribution were evaluated under impact conditions at 50 and 80 km/h. The results obtained were compared with the conventional PC/ABS material, demonstrating that P-GLASS/ABS exhibits competitive structural behavior, with adequate resistance to dynamic loads and energy absorption capacity within acceptable ranges for critical non-structural components. It is concluded that manufacturing the headlight using 3D printing with an alternative material is technically feasible, provided that experimental validation criteria and prior simulation are considered to guarantee mechanical performance and functional safety in automotive applications.