The integration of additive manufacturing technology and biomimetic design provides new possibilities for functional and aesthetic innovation in automotive interiors. This study explores a roof handrail design method based on a spider web biomimetic structure from the perspectives of object character and design freedom. By transforming the spider web morphology of nature into a manufacturable parametric model, the organic unity of structural performance and visual aesthetics has been achieved. The simulation results show that the spider web biomimetic structure handrail distributed along the z-axis not only meets the mechanical performance (maximum stress of 189.11 MPa under 1500 N load) but also theoretically reduces weight by 32.03% compared to traditional designs. Material testing shows that the spider web biomimetic structure handrail made of PA6-CF material through fused deposition molding not only meets safety requirements but also has a better user experience. This study achieved organic forms that are difficult to process with traditional techniques through 3D printing technology, providing a new paradigm of “form following ecology” for automotive interior design and expanding the possibilities of functional components in user experience and spatial narrative.

This study utilized a twisted wire rotating arc cladding method to in situ fabricate a Fe-containing multi-principal element alloy (HPEA) coating derived from NiCrCoTiMo stranded wire on 45 steel (equivalent to AISI 1045 steel). The macroscopic morphology, microstructure, mechanical properties, and electrochemical corrosion behavior of the prepared coatings were examined. The coating exhibited no visible cracks or pores and displayed a dual-phase face-centered cubic (FCC) + body-centered cubic (BCC) structure, with an average grain size of 78 μm for the FCC phase and 1 μm for the BCC phase. The microhardness of the coating is approximately 381.3 HV_0.1. Compared to 45 steel, the coating’s coefficient of friction (COF) decreased from 0.6265 to 0.5125, representing an 18.2% reduction. The calculated wear rate of the coating was 1.47 × 10⁻⁵ mm³/N·m, approximately six times lower than that of 45 steel (8.93 × 10⁻⁵ mm³/N·m). Electrochemical testing revealed that the coating’s open-circuit potential (OCP) was −0.405 V vs. the saturated calomel electrode (SCE), with a corrosion potential (E_corr) of −0.556 V vs. SCE and a corrosion current density (I_corr) of 4.458 × 10⁻⁶ A/cm². In comparison, 45 steel exhibited an OCP of −0.582 V vs. SCE, with corrosion parameters of E_corr = −0.840 V vs. SCE and I_corr = 1.302 × 10⁻⁵ A/cm². These results demonstrate the superior corrosion resistance and wear performance of the coating, underscoring its potential for applications in challenging environments that demand enhanced material durability.

Cable wires provide a viable technical pathway for the laser additive manufacturing of high-entropy alloys (HEAs). However, the complex interplay of structural and material parameters of cable wires leads to significant variations in molten pool dynamics, which poses challenges to the fabrication of high-quality HEA coatings. To clarify the effects of these key factors on molten pool behavior, a multi-physics numerical model for the laser cladding of Al₅₀Si₆Ti₈Cr₁₂Cu₁₂Ni₁₂ cable wires was established in this study. A dedicated physical model for cable wires was developed, and the Level Set Method was employed to track fluid interfaces throughout the cladding process. Based on the proposed model, the temperature distribution, stress fields, and elemental homogeneity within the molten pool were systematically investigated. The results reveal that chromium (Cr) addition induces a viscosity reduction, and a torsional pitch of ≤4 mm is critical for achieving defect-free, compositionally uniform HEA coatings, which provides novel insights for process optimization and alloy design of cable-wire laser cladding.