3D printing for automotive industry!

Industry sector: Product development service

Objective: Utilize the design freedom associated with 3D printing to customize products for specific clients, improving their performance versus traditionally manufactured parts.

Approach: Redesign mechanical components to benefit from the unique capabilities of 3D printing, helping them make better use of space while also performing more effectively. Rapidly prototype to improve product development cycle times and reduce costs by producing parts in short runs.

Technology: HP Multi Jet Fusion

Summary: IAM 3D Hub aims to accelerate the adoption and development of 3D printing technologies in the European Union’s manufacturing sectors. Located in Spain’s Catalonia region, the Hub helps integrate and coordinate activity in the additive manufacturing ecosystem and provides its customers with an alternative way to design, develop and manufacture new competitive products and services. IAM3DHub was formed as part of a collaboration between several industry giants, including HP and Renishaw, Coniex, which provides process consulting, and LEITAT, which is a non-profit research organization that specializes in material, device and production technologies. In addition to additive manufacturing, the Hub also provides support with materials science and engineering. The company supports clients in many different industries including: automotive, aerospace, locomotive and other transportation companies, in addition to leaders in energy, healthcare, and consumer goods, among others. I AM 3D Hub addresses the potential of 3D printing throughout a product’s value chain, from design, to production and ongoing maintenance and support. Some of the applications it offers include conceptual models, prototypes, tooling for traditional manufacturing processes, end-use products, spare parts and more.

Here are two case studies, where 3D printed parts were efficiently used:

HP Multi Jet Fusion simplifies production of race car manifold

Heli Racing is an amateur sports racing team based in Belgium. Since the 2016 racing season, Heli Racing has invested in a newer, faster car that combines their current fuel-efficient diesel engine with the performance of a fast touring car. With this car, they will return to the Belgian Gentleman Drivers Club (BGDC) and Belcar’s Belgian Endurance Championship.

The challenge

The Heli Racing car, a BMW 120d, incorporated a manifold made with two Injection Molded half-parts glued together. This manifold—a standard industrialized part from BMW—did not meet racing requirements: It would burst during the race when the glue joint between the two half-parts was not strong enough to resist pressure and thermal conditions.

Results

Using 3D scanning methods and reverse engineering, the manifold has been replicated digitally and improved with some technical adjustments.

• The manifold was 3D printed in just one part to prevent problems with glue sealings. The 3D printed manifold performed very well during racing, where it withstood a pressure of 3 bar and temperatures of up to 80ºC. 3D printing with HP Multi Jet Fusion technology also resulted in:
• Enhanced performance: The 3D printed manifold withstood a pressure of 3 bar and high race temperatures of up to 80ºC.Reduced number of parts: Rather than relying on a two-part manifold that is held together by glue, the HP MJF manifold was 3D printed as only one part.

Custom 3D printed car parts for motorsports team

Motor L’Escala is a company that sells cars and motorbikes, and offers various after-sales services. The Motor L’Escala Racing Team’based in L’Escala, Girona (Spain)’participates in the annual amateur Panda Raid rally competition, a long-distance car race from Madrid, Spain to Marrakech, Morocco.

The challenge

The team wanted to upgrade their car’s engine using HP Multi Jet Fusion (MJF) technology. After the replacement process, they realized that the new engine’s complementary features, such as the air filter box, didn’t fit as expected under the hood. They had to remove the original air filter box and some of the ducts to integrate new customized parts (i.e., the filter cover, the filter housing, and the collector) into the remaining available space under the hood.

Results

With the help of HP MJF, the team produced 3D printed parts that offered:

Customisation: Using 3D printing, the team was able to design the parts just as they needed rather than having to apply modifications.

Air tightness: The team benefitted from the tightness of HP MJF materials to ensure that the parts performed consistently well in various weather and terrain conditions along the competition route.