A novel computational design tool to calculate the elasto-kinematic flexure hinge properties is presented. Four hinge contours are implemented. It is shown, that FEM results correlate well with the analytical design tool results. For a given deflection angle of 10° and a corner-filleted contour, the deviations of the bending stiffness are between 0.1 % and 9.4 %. The design tool can be beneficial for the accelerated and systematic synthesis of compliant mechanisms with optimized flexure hinges.

A Composite material (Carbon fiber reinforce polymer) leaf spring has been used to efficiently integrate the functions of suspension control arm and anti-roll bar in a compact passenger suspension. Composites materials were chosen to tailor the required behavior of the leaf spring and to reduce the weight. The research is done with multiple simulation methods, such as MBD and FEM. DoE is also performed to find the best combination of variables in the model.