This report includes development of an already designed solar water heater. The product shall be constructed in a way that it will suit a manufacturing line in Kampala, Uganda. To find the most suitable design for each area a research was carried out which included study visits, interviews and background reading. It provided the following results: Regarding the attachment of in- and outgoing pipes from the water tank many methods were taken into consideration and it was found that the best and most suitable way for this case is to weld the fittings using a weld robot. Regarding the fitting of the acrylic, a suitable solution is to make a flange when vacuum forming the plastic casing to further support the design. This could also be used to waterproof the case by using a sealing material. A suggestion of using pre-molded PU-foam is also presented. Regarding the ability to open the case for maintenance, two solutions were recommended. Either the use of spire clips or having the clips integrated into the casing. Regarding the calculation of material usage when deep drawing the tank and collector, it is possible to do a reasonably accurate assumption. The complicated design in this product makes the estimation less accurate. It is recommended that test draws are done and often the machine producer has more precise numbers. Regarding the coloring of the collector; chemical coloration is not possible on a galvanized surface. The method used is painting, either with powder coating or with wet paint.

Hat sections, single and double, made of steel are frequently encountered in automotive body structural components such as front rails, B-Pillar, and rockers of unitized-body cars. These thin-walled components can play a significant role in terms of crashworthiness and impact energy absorption, through a nonlinear phenomenon called as progressive dynamic buckling. As modern vehicle safety design relies heavily on computer-aided engineering, there is a great need for analysis-based predictions to yield close correlation with test results. Although hat sections subjected to axial loading have been studied widely in the past, there is scanty information in published literature on modeling procedures that can lead to robust prediction of test responses. In the current study, both single-hat and double-hat components made of mild steel are studied extensively experimentally and numerically to quantify statistical variations in test responses such as peak load, mean load and energy absorption, and formulate modeling conditions for capturing elasto-plastic material behavior, strain rate sensitivity, spot-welds, etc. that can lead to robust predictions of force-time and force-displacement histories as well as failure modes. In addition, keeping initial stages of vehicle design in mind, the effectiveness of soft computing techniques based on polynomial regression analysis, radial basis functions and artificial neural networks for quick assessment of the behaviors of steel hat sections has been demonstrated. The study is extended to double-hat sections subjected to eccentric impact loading which has not been previously reported. A lightweight enhancement of load carrying capacity of steel hat section components has been investigated with PU (polyurethane) foam-filled single and double hat sections, and subjecting the same to quasi-static and axial impact loading. Good predictions of load-displacement responses are again obtained and shortening of fold lengths vis-à-vis hollow sections is observed. Finally, the performance of hat sections made of glass fiber-reinforced composites is studied as a potential lightweight substitute to steel hat section components. The challenging task of numerical prediction of the behaviors of the composite hat sections has been undertaken using a consistent modeling and analysis procedure described earlier and by choosing an appropriate constitutive behavior available in the popular explicit contact-impact analysis solver, LS-DYNA.