News and Insights of 3D Printing and Manufacturing
Sakuu Corporation, developer of the world’s first rapid printed battery, today announces that its first-generation non-printed lithium metal battery has achieved continuous 3C discharge rate under extensive testing, marking yet another achievement on the road to mass 3D printed solid state batteries.
We have been arguing on these pages that the incredible dominance of Mercedes in Formula 1 for the past decade was due in part to the team’s ability to heavily implement AM for both development and optimized parts (and we’ve had sources confirm this). We’ve also argued that Scuderia Ferrari’s failures during the past decade were due to the team’s reticence in adopting AM technology, especially in terms of reliability. Things seem to be turning around with the 066/7 power unit of the new F1 75 car for the 2022 season.
The Stellantis group has been eyeing 3D printing for some time, especially through the activities of its French PSA (which includes PEUGEOT and Citroën) component. PSA has made deals with Divergent 3D and introduced experimental printed parts – even metal ones, – for Citroën cars. The Italian-Amerian side of the company, FCA, has been working on prototyping for over two decades, with the famous example of the Alfa Giulia’s front grill. More recently the company has been working with MJF technology for production components on its Jeep branded cars and other long-term conceptual projects. Now it’s all coming together with commercial MJF 3D printed accessories for the PEUGEOT 308.
Alfa Romeo F1 Team ORLEN unveiled a new partnership with the Camozzi Group, the global leader in the production of components and systems for high-tech industrial automation. The partnership, both a technological and sporting venture involving Sauber Technologies, is based on the two companies’ commitment to delivering excellence through cooperation and shared synergies.
Sauber Technologies has extended its technology partnership with metal additive manufacturing leader, Additive Industries for a further three years. Sauber Technologies has been using Additive Industries’ MetalFAB platform for metal additive manufacturing (AM) since 2017, with a current count of four systems in-house as the company embarks on new, ambitious projects for third-party customers. Sauber Technologies is also part of the same group as Alfa Romeo F1 Team ORLEN.
Czinger Vehicles is expanding its global reach, with H.R. Owen as its first international retail partner and exclusive Czinger dealer in the U.K. The alignment opens up the European market to the Los Angeles-based automotive brand as sales begin for its first production car, the pathbreaking 21C, a marvel of modern engineering which integrated dozens of 3D printed parts in its body structure.
Airtech Advanced Materials Group, a leading manufacturer of composite tooling solutions, has announced that it has been named a Brumos Racing Technical Partner. Airtech has teamed up with BBi Autosport to produce 3D printed molds and composite production parts for a newly updated Porsche GT2 RS Clubsport racecar, for the Brumos Racing team. Helmed by racing legend David Donohue, and brandishing the Brumos Racing livery, this state-of-the-art vehicle can be seen in competition at the 100th running of the Pikes Peak International Hillclimb on June 26, 2022.
According to a story first published by TheDrive, “all models referencing the word Honda posted prior to March 30, 2022, were seemingly removed from Printables without warning. These included speaker brackets, key housings, hood latches, shifter bushings, washer fluid caps, roof latch handles, and my trunk lid handle—a part not offered on 10th generation Accords sold in the U.S. at all. According to the author of the article, many of the removed parts had no Honda branding but were just compatible with Honda vehicles. As it turns out, Prusa says it was issued a takedown notice from Honda and removed all 3D models that referenced the brand.
When General Motors was unable to produce a component needed for the delivery of the 2022 Chevrolet Tahoe, the company’s engineers turned to 3D printing, as many companies facing supply chain challenges are doing, increasingly.
EOS, a leading supplier of industrial 3D printing technology, and Sauber Technologies, the company devoted to bringing Sauber’s Formula One mindset and innovation to businesses all over the world, signed a three-year AM technology partnership at the F1 Grand Prix in Barcelona, Spain, last weekend. The partnership includes installation of a new EOS P 500 for polymer parts production.
Conflux Technology has used its extensive knowledge in additively manufactured heat exchangers to deliver its first product: a premium, scalable, configurable, ultra-high performing water charge air cooler (WCAC) that outperforms other leading WCACs, applicable to motorsport and high-end automotive markets. The Conflux WCAC is configured to specific customer requirements and has been launched with a focus on performance, competitive pricing, and rapid delivery.
The Industrialization and Digitization of Additive Manufacturing project (IDAM project) for automotive series processes has been successfully implemented. The project consortium, funded by the Federal Ministry of Education and Research (BMBF), and led by the BMW Group, started three years ago with small and medium-sized companies, large companies, and research institutions. All members had a common goal – to revolutionize metallic 3D printing in the field of automotive series production.
After the story we reported on the team’s use of metal AM for the cylinder block, Scuderia Ferrari F1 has turned to 3D printing again, this time for polymer PBF 3D printed sensor mounts, fitted on the F1-75 during the Formula 1 Australian Grand Prix Friday practice session.
The world’s first additively manufactured car engine piston, made entirely with ceramic, has been developed by Spyros Panopoulos Automotive (SPA) for its Chaos Ultra car using XJet technology.
An M1 Metal AM System from Dutch company MX3D is going to be installed at the Additive Manufacturing Campus of BMW Group in Munich, Germany. With the M1 Metal AM System, BMW Group has acquired one of the most advanced setup the market has to offer with respect to Robotic Wire Arc Additive Manufacturing (WAAM). This will allows the company’s engineers to explore the potential of this highly flexible and productive method of metal additive manufacturing.
Australian additive manufacturing company, SPEE3D, showcased their world-leading metal 3D printing technology at the Melbourne Grand Prix.
Using Additive Manufacturing technology, the Formula Student Racing Team E-Stall of the University of Applied Sciences Esslingen, Germany, improved cooling of the electric drivetrain and power electronics. Printed with the highest accuracy on the EP-M260 by Eplus3D, the aluminum-made parts were able to easily dissipate the generated heat and therefore improve the performance of the racecar.
REFORM, the vehicle specialist, develops and manufactures special vehicles for year-round use in mountain agriculture and municipal areas. For flexible and innovative product development, the company relies on additive manufacturing and the Upper Austrian 3D specialist Prirevo.
ŠKODA AUTO revealed it is now employing 3D printing for the production of components, spare parts and tools. The Czech car manufacturer is making its production and logistics more flexible and efficient by using a 3D print farm based on systems from local material extrusion 3D printer manufacturer Prusa, founded by the industry legend Josef Prusa. The Confederation of Industry of the Czech Republic (Svaz průmyslu a dopravy České republiky) recognized the ‘More flexible with 3D print farms’ project, considering it one of the five most innovative Industry 4.0 applications from the past year in the country.
Sparks flew as Bugatti tested its generatively designed 3D printed brake caliper, additively manufactured with SLM Solutions technology. Volumetrically this part is the largest functional titanium component built with SLM technology.
SLM Solutions has started a cooperation with MAHLE, one of the leading automotive suppliers and development partners from Stuttgart, Germany. MAHLE will utilize SLM Solution’s systems to empower OEMs and Tier 1 suppliers to fulfill their need for metal Additive Manufacturing in serial production. By joining forces, the two companies are improving the speed and quality of automotive components in both prototype and serial production.
Olli 2.0, the autonomous electric vehicle from the ground sustainable mobility company Local Motors, now includes 3D printed parts manufactured by CRP Technology using Windform composite materials.
Conflux Technology, an Australian studio developing some of the most advanced additively manufactured heat exchanger designs, will be producing a new set of 3D printed heat exchangers in partnership with Dallara, Italy.
Remember the LSEV? The largely 3D printed EV from a mysterious company called XEV? We first reported on this project back in 2018, when some overly hyped-up stories announced the car was ready for mass production. Back then we were at least able to confirm the project was real and real it is. It took a bit longer than the original 2019 timeline for launch, but the car is here, it’s real and it’s already zooming around. In fact, the official launch of the YOYO (the new name of the LSEV) took place in May 2021. XEV’s first fully electric city car can be driven from the age of 16 with a B1 licence.
Desktop Metal (NYSE: DM) received a $7.9 million order for binder jet additive manufacturing systems from a major German carmaker for the mass production of metal automotive powertrain components at scale. Considering the BMW was (and is) among Desktop Metal’s first investors via its BMW i Ventures, that Volkswagen is actively working with HP, and that Daimler Benz (Mercedes) has done a lot of work with EOS, we guess (and we stress the word “guess”) that the major German carmaker is BMW.
When it was first presented, the MIT Self Assembly Lab’s liquid-in-liquid 3D printing process received an enormous amount of press coverage and visibility. I have to admit that we were skeptical about it. Then BMW started to play with it and demonstrated that Rapid Liquid Printing technology held great promise for rapid elastomer applications in the automotive segment. That’s when we began to understand the technology’s potential. Now BMW got even more serious with it and, through its BMW i Ventures (which has funded other successful ventures in AM such as Desktop Metal) led an investment in the seed financing round of Rapid Liquid Print (RLP), and its gel-printing technology. RLP uses industry-standard materials, such as soft rubber, silicone and foams, to produce soft, flexible products without retooling or post-processing. Also participating in the round is MassMutual through the MM Catalyst Fund (MMCF).
The Mission R is the latest vision from Porsche. With this study of a fully electric GT racing car, the pioneer for sustainable mobility shows what customer motorsport could look like in the future. And the 3D printed lattice seats ensure maximum comfort.
Uniformity Labs (Uniformity) has successfully printed an additively designed automotive component with its ultra-low porosity AlSi10Mg, a high throughput, aluminum alloy powder that exhibits optimal material properties. The Uniformity AlSi10Mg powder and optimizing print processes have previously been deployed with a variety of parts in various industries with great success.
Brose, a global automotive supplier, is now confirmed as one of the first participants in the High-Speed Sintering (HSS) Early-Access Beta Program for the VX1000 HSS 3D printer. The company will work with voxeljet AG as a cooperation partner to further develop the VX1000 HSS for use in additive series production of polymer components for the automotive industry. With HSS, voxeljet combines the advantages of two existing additive technologies: selective laser sintering and binder jetting, giving the benefit of both SLS part properties and binder-jetting productivity. The new VX1000 HSS 3D printer has a significantly larger build volume and a faster print speed than previous systems, enabling true additive series production.
Sakuú Corporation, a company leading the development of an automated multi-material multi-process additive manufacturing to produce 3D printed SSBs (solid-state batteries), today closed a follow-on financing round bringing total funds raised to date to $62M. This funding bolsters the company’s ability to commercialize its first-generation solid-state batteries and bring to market the world’s first multi-material multi-process additive manufacturing platform that will 3D print its second-generation SSBs and other active devices.
Divergent Technologies harnesses the power of additive manufacturing to unleash innovation in the automotive industry, making them a global innovator in the advancement of economical serial production. They have developed a state-of-the-art Divergent Adaptive Production System (DAPS), which will now be strengthened with the addition of three production SLM NXG XII 600 systems, following a years-long development partnership with SLM Solutions. Deliveries of the machines will start in Q1 2022.
BCN3D released a complete reinvigoration of their current BCN3D Cloud platform. The new web-based cloud will allow companies to scale up their additive manufacturing operations and make entire printing workflows more efficient, controlled, and easier than ever before.
Following some final adjustments, the customized 3D-print bodyform full bucket seat is now available as part of the new Performance Parts offering from Porsche Tequipment. The seat is suitable for various Boxster, Cayman and 911 models. From February 2022 onwards, it can also be ordered from Porsche Exclusive Manufaktur as a standard feature and it will be integrated into the Porsche Car Configurator at this point too. In addition to its unique look, the new central section of the seat is its main innovation: parts of the cushion and backrest surfaces are produced using a 3D printer and are available in three different rigidity grades, meaning the seat can be customized to suit the customer’s specific needs.
(Co-)created by Paul Smith, The MINI STRIP is a custom-made one-off car which has resulted in these two iconic British brands sharing creative thoughts on sustainable design for the past few months. Considering that the car has been made to be both sustainable and unique, 3D printing naturally has to play a part and did so in several parts made with recycled polymers through an extrusion process.
Perrone Robotics, Inc., a provider of fully autonomous vehicle (AV) technology, and Local Motors Inc., a manufacturer of largely 3D printed shared electric autonomous shuttles, have signed an original equipment manufacturer (OEM) agreement. The two companies have agreed to develop next-generation autonomous shuttles that will integrate Perrone’s autonomous vehicle technology into Olli, the shuttle designed and manufactured by Local Motors.
Rapid Parts Solutions, or RPS, is located in Shenzhen, China, the capital of commercial passenger car manufacturing. As part of the automotive ecosystem, RPS is the chosen part supplier for many tier 1 car manufacturers, offering rapid fabrication of prototyping to series production. RPS added two Farsoon Flight HT403P machines as an expansion of their manufacturing capabilities, offering comprehensive solutions of digital models, production, post-processing, and final products.
In an effort to highlight its commitment to technology, Eastern Michigan University’s (EMU) GameAbove College of Engineering and Technology will deploy autonomous Olli smart EV shuttles this school year as it will open a new research and development space at the American Center for Mobility (ACM) in Ypsilanti, Mich.
Daimler Buses and its service brand Omniplus have created a mobile 3D printing center for the decentralized production of spare parts in order to be able to provide bus customers with replacements more quickly. The “mini-factory” in the form of a container includes all of the stations relevant to the production of spare parts using a 3D printer on an area of only 36 square meters. The twelve-by-three-meter container can be transported by truck to any location. Once there, only electricity and an internet connection are required for its operation.
Sakuu Corporation (previously KeraCel Inc.), a pioneer in automated multi-process additive manufacturing (AM), presented a new industrial-grade battery 3D printer, developed specifically for e-mobility batteries. The breakthrough technology is intended to unlock the mainstream adoption of EV and e-mobility vehicles by solving the previous issues of cost, performance, sustainability, and range. Offering an industrial scale ‘local’ battery production capability, the Sakuu technology is likely to significantly expedite the use of EV’s, by providing increased manufacturer and consumer confidence.
CHAMPP, an Alloyed‘s consortium, has been awarded a significant grant to research, develop and test an innovative new hybrid production process that will address a number of the key limitations of additive manufacturing for the automotive sector, specifically electric vehicles (EVs). The Casting-Hybrid-Additive-Manufacturing-Parts-Production (CHAMPP) program brings together a critical mass of technical and market expertise with three key partners, namely Alloyed, Brunel University London’s BCAST, Gestamp, and its affiliate Autotech.
Massivit 3D’s in-depth knowledge of large-scale additive manufacturing has evolved over the years. Many, for instance, will know of how its 3D printers are used to produce large-scale objects—including the DB Project full-scale concept car—for marketing and entertainment purposes. But its technology is also capable of much more. Its newest machine, the Massivit 10000, is built for tooling applications in the automotive, railway, marine, energy and other industries. More specifically, the Massivit 10000 seeks to reinvent how large-scale fiber-reinforced composite parts are fabricated.
A novel cooling system in the Ethec City electric motorcycle ensures a longer service life for the battery cells. In order to introduce the students to manufacturing processes that can be used for series production outside of prototype manufacturing, voxeljet produced the mold for the innovative battery housing of the prototype using the binder jetting process. A student focus project at ETH Zurich is realizing prototypes of a new type of cooling system with support from voxeljet.
Local Motor‘s recent deal with door2door to bring its smart 3D printed EVs to Germany shows that the new generation of smart EVs is on the way. Local Motors was among the companies that first leveraged the concept of a distributed automated factories and it did so by making heavy use of LFAM composite 3D printing for large sections of the Olli vehicles. Arrival may be the first company to fully deploy highly automated Arrival Microfactories to produce an entire family of next-gen EVs. However, while the company has shown heavy use of robots it has not yet made any reference to implementing 3D printing processes for parts production.
During a recent online webinar, Lamborghini’s Edoardo Trabace, Procurement Lead at Automobili Lamborghini, Jacopo Bardocci, R&D Lead for Additive Manufacturing at Automobili Lamborghini, Gabriele Grezzana, R&D Engineer at Automobili Lamborghini, and Norik Elchibegian, Director of Enterprise Partnerships at Carbon, discussed the importance of reducing time to market and the power of internal partnerships to push forward innovation and make better parts faster.
3D Systems confirmed the availability of Accura Composite PIV – a new material specifically designed to address PIV testing applications used primarily in motorsports wind tunnel testing. Developed in collaboration with the Alpine F1 Team (formerly Renault F1 Team), Accura Composite PIV is capable of producing rigid parts in a high-contrast color optimized for PIV testing. Parts produced using this material take significantly less time to prepare – from CAD to wind tunnel – and deliver more accurate, high-resolution data. When used as part of a complete 3D Systems additive manufacturing solution – comprising Accura Composite PIV, the company’s stereolithography (SLA) technology, software, and advanced application services – Alpine F1 Team has been able to maximize its wind tunnel investment and improve its understanding of the airflow over the car.
Alfa Romeo Racing ORLEN takes another step forward in the realm of technological innovation as the organization unveils a partnership with AM Solutions, a brand of the Rösler Group. As part of the agreement to bolster the team’s post-processing of additively manufactured parts, Alfa Romeo Racing ORLEN will acquire three S1 systems by AM Solutions – 3D postprocessing technology to bring the automation, economic efficiency and repeatability of its post-processing to the next level.
Gryp, a French specialist in the reproduction of automotive parts by 3D printing, is structuring the development of its constantly growing activity by joining forces with the Bordeaux-based startup Handddle to industrialize its manufacturing processes. The new Handddle SMART FARM 3D printer networking solution will enable Gryp to produce more, faster, in better conditions and at lower costs.
Volkswagen is pressing ahead with the use of innovative 3D printers in car production. For the first time, metal binder jetting is being used to manufacture components at the company’s main plant in Wolfsburg, Germany.
Local Motors, a leader in the design, manufacturing, and deployment of autonomous vehicles, and Protean Electric, a specialist of in-wheel motor technology for passenger cars, light commercial vehicles and future transport solutions, have expanded their long-standing partnership, inking a further three-year deal valued at $7.3 million. Under this significant new order, Protean Electric will deliver thousands of its ProteanDrive in-wheel motors (IWMs) to power Local Motors’ largely 3D printed Olli 2.0 electric autonomous shuttles, accelerating the rollout of state-of-the-art vehicles around the world.
In the beginning, it was the Blade, a concept hypercar featuring the first fully 3D printed frame and a number of other 3D printed parts. That early concept was used by the startup Divergent 3D to raise funds and acquire multiple production metal 3D printers from SLM Solutions; today it has evolved into the Czinger 21C a finished hypercar, the first such vehicle ever built using no tools and featuring an unprecedented number of fully 3D printed parts.
BCN3D, a Spanish 3D printing solutions manufacturer, has been working with the automaker Nissan to successfully integrate 3D printing into production processes at the automotive giant’s Barcelona factory.
Sakuu Corporation (previously KeraCel Inc.), a specialist in automated multi-process additive manufacturing, obtained three patents related to EV battery 3D printing; a hybrid solid-state cell with a sealed anode structure, an additive manufacturing system with the ability to create an active device such as a micro-reactor or solid-state battery, and an electrophotographic multi-material 3D printer.
Only 5% of the Moon’s surface has been explored by the human race, and to reach the other 95%, NASA astronauts on the Artemis program are going to need some serious wheels. That’s why Lockheed Martin and General Motors have teamed up to design a next-generation lunar rover, capable of transporting astronauts across farther distances on the lunar surface. While the rover doesn’t need to be lightweight to travel around the Moon, it will certainly have to be extremely lightweight in order to be transported from the Earth’s surface (where it will likely be assembled, until there will be AM factories available in space) to the surface of the Moon. For this endeavor, Lockheed Martin and GM—with both companies already quite familiar with using AM—may want to turn to SLM Solutions. The metal AM hardware manufacturer has built up experience with building both lunar rovers and cars.
Local Motors, a leader in the design and manufacturing of autonomous vehicles, and door2door, a Berlin-based leader in mobility software, have formed a new strategic partnership. Together they want to use the strengths and experiences of both companies to drive autonomous mobility to the next level.
Local Motors recently began the first-ever project autonomous vehicle project moving packages around Marine Corps Air Station (MCAS) Miramar using the Olli autonomous electric shuttle.
Today more than 50% of Lamborghini cars coming off the production line feature at least one Ad Personam feature. At Bugatti, not one car that leaves the Atelier is like the next, having the highest degree of individualization. It should come as no surprise that VW brands Lamborghini and Bugatti are the ones that have conducted the most experimentation with 3D printed parts, among the established supercar brands.
Imagine ultra-lightweight components that are as strong as a reinforced concrete column. Now, as Volkswagen reports in its new blog, this is possible, thanks to technology-led by Bugatti engineers. The newly developed 3D printed pushrod – a pressure-loaded coupling rod in the chassis area – weighs just 100 grams and can transmit forces of up to 3.5 tonnes. The hollow titanium structure with an internal supporting arch gives incredible strength and is yet another AM breakthrough among several Bolide 3D printed parts recently introduced by Bugatti.
What was a promising experiment in automotive 3D printing has apparently come to an end. While doing some follow-up research for our upcoming Automotive AM eBook, I clicked onto the MINI Yours Customised home page, eager for an update on the personalization service launched by BMW back in 2018. Sadly, I was greeted by a succinct message, stating that the custom automotive program was no longer.
Ford Spain is the first car manufacturer in Europe to use the Form 3L, a larger format 3D printer from photopolymerization 3D printer OEM Formlabs. Ford Body and Assembly in Valencia uses the Form 3L to produce plastic caps that are used in a vacuum test to check engines for leakages. 3D printing helps Ford to prototype new tools and produce specific parts in less time and for a lower cost than with traditional manufacturing.
Callum Automotive installed MakerBot‘s METHOD X 3D printer to produce functional prototypes, tooling, and production parts. Callum’s luxury automotive design business focuses on luxury vehicles and associated lifestyle brands, including the limited edition Aston Martin Callum Vanquish 25 by R-Reforged.
The MINI Electric Pacesetter inspired by JCW is the new safety car of the ABB FIA Formula E World Championship racing series and thus connects the brand’s electrified future with the rich racing history of John Cooper Works. The vehicle, which also sports unique, generatively designed, 3D printed seats, was created on the basis of the new MINI Cooper SE in a previously unique collaboration between MINI Design, BMW Motorsport, the FIA and Formula E.
PWR Performance Solutions, based in Australia, decided to look into adding metal 3D printing technology to its current workflow, to stay at the forefront of manufacturing capacity. The heat exchanger pictured above was designed by PWR to test the capabilities of different aspects of 3D printing. PWR engineers designed the fin structure and tube array as a benchmark for testing minimum wall thickness, surface finish, and heat transfer efficiency. To produce the parts, PWR chose E-plus 3D as a supplier and ordered an EP-M250Pro MPBF system.
AUDI AG, a leading manufacturer of premium vehicles, is relying entirely on industrial 3D printing at its Metal 3D Printing Centre in Ingolstadt for the production of selected tool segments. Additive manufacturing (AM) with EOS technology is used for 12 segments of four tools for hot forming. Plans call for significantly more segments to be printed this way. Audi uses the tool segments produced using the EOS M 400 system in its press shop to make body panels for models including the Audi A4. The company plans to do the same for future electric vehicles.
The hottest competition is in metal binder jetting and so it happens that, on the same day, two leaders in this field make a comparable breakthrough announcement: the ability to 3D print aluminum 6061 alloy by binder jetting and, more importantly, to proficiently sinter it. ExOne achieved this aluminum binder jetting breakthrough by working with Ford Motors Company on a new patent-pending process.
PIX Moving is working to reshape the future of city life by fully exploiting autonomous mobility and bringing mobility to traditionally fixed brick and mortar business spaces. The team developed many electric chassis platforms of various sizes, that customers use as a base to develop their ideas. A few days ago we reported on the company’s unique use of generative design and WAAM technology. Now Mechanical Design Engineer Siddharth Suhas Pawar expands on that, presenting the business case for the use of WAAM processes in actual production.
Stratasys is buying an Industrial SLA system manufacturer? 3D Systems answers by introducing an industrial filament extrusion 3D printer: a novel High Speed Fusion (HSF) industrial 3D printer platform and material portfolio. Based on material extrusion technology and developed in a collaboration with Jabil Inc, this unique HSF family of products, including the Roadrunner 3D printer, is expected to provide the best economics of any high throughput industrial fused-filament offering in the market today. Through the use of advanced electric motion control, this unique system operates at speeds and precision levels well beyond current state-of-the-art production platforms. With temperature capability and available build areas greater than those of competing systems, combined with an outstanding materials portfolio, the Roadrunner system is designed to address the most demanding aerospace and advanced automotive applications. The result is not only unique application solutions but compelling manufacturing economics driven by the size, speed, and precision of this new technology platform.
In 2019, PIX turned to WAAM (wire arc additive manufacturing), then an emerging AM technology that used a combination of an electric arc as heat source and a metal wire as feedstock. The result chassis was much lighter and easier to produce, thus reducing costs for PIX, whose goal is to provide cities with sustainable autonomous mobility.
There is untapped potential for 5G, the newest, fastest wireless communication band, in the large automotive market. Rhosoon Intelligent Technology Co. has used Farsoon‘s 403P laser powder bed fusion system to realize some of this latent potential.
Swiss motorsport company Sauber is a historic team in the Formula 1 circuit, where it has been competing since 1993. The intensive implementation of AM at Sauber since the early 2000s is not the only reason why the company is now playing such a relevant role in the AM industry: Sauber Engineering was established to leverage the team’s unique engineering know-how and provide design and production services using Additive Industries’ MetalFAB1 metal 3D printers. Last year this led to the production of over 22,000 metal laser PBF printed parts; and these are just the start.
Reducing vehicle weight reduces CO2 emissions and remains a key concern for auto manufacturers. FEV and its partners in the LeiMot (Lightweight Engine) research project use additive manufacturing to demonstrate further combustion engine emission economies. FEV engineers were able to make engine functions, such as cooling or oil circulation, more efficient. Large assemblies of a passenger car reference diesel engine weight in around 21 percent lighter.
As one of the first customers, OECHSLER, one of the largest volume manufacturers of 3D printed plastic components, has purchased the S1 post-processing system from AM Solutions – 3D post-processing technology. The automated S1 will assist the company to fulfill the stringent requirements for quality, repeatability of processing results, traceability and cost efficiency that must be met in the automotive industry.
The brief for the McLaren Artura was even more challenging than its predecessors: to create a series-production High-Performance Hybrid supercar that excels on every level, with performance, engagement and efficiency sharing equal top-billing. The engineering and design team approached the challenge holistically – no single part of the process was undertaken in isolation – with ambitious targets set in every area: weight; performance; driver engagement; efficiency; agility; refinement; quality and usability. Of course, 3D printing had to play a part. McLaren confirmed the use of 3D printed cores in the engine production process, however, 3dpbm suspects other parts of the chassis and powertrain were directly printed as well.
The following is a preview of an interview conducted by 3dpbm with General Motors. Look out for the full story in our upcoming Automotive AM Focus 2021 eBook.
ANM (Azienda Napoletana Mobilità S.p.A.), the traditional Neapolitan public transport company, is collaborating with local AM service provider 3DnA to restore and maintain the mobility of its lines in the city of Naples. The production of needed replacement parts was made possible by re-engineering and 3D printing mechanical components no longer available from their supply chain, where the original technical documentation and drawings could not be recovered.
Elisava Racing Team is creating a fully electric, intelligent motorcycle equipped for mountain rescue in hostile terrains. Collaborating with BCN3D, 19 end-use parts were printed using FFF technology in a variety of different technical materials and sizes.
I wanted to inspire people to use 3D printers to build real robots, so I built this car ...
Bugatti routinely uses this innovative 3D printing technology to enhance components with complex thr ...
1016 Industries is planning to debut its first full-body 3D printed kit at the beginning of 2021. The company plans to provide directly printed tooling molds for the McLaren 720S and other supercars as well in the near future, with the goal to manufacture products directly as 3D printed parts.
Swiss firm Blackstone Resources has achieved a series of important milestones for its proprietary 3D printing technology to print lithium-ion solid-state batteries. The company has been investing in the next generation of battery technology through its German subsidiary Blackstone Technology GmbH. This includes patented 3D printing techniques and research into the mass production of batteries, which has been shown to offer greater energy density and a higher number of charging cycles.
In this edition of Sliced, the 3D Printing Industry news digest, we cover the latest business developments, partnerships, and acquisitions across the additive manufacturing industry.
Desktop Metal has begun shipping a new, intermediate version of its P-50 Production System, the new P-1 printer, globally to its early customer base. Key clients who have already received the machine include Ford Motors, an early investor in Desktop Metal, and Cetim, the Centre Technique des Industries Mécaniques, in France, which is the first European institution to receive it. The P-50 remains on schedule to begin volume commercial shipments in 2021: achieving this milestone will be a key passage in DM’s strategy for growth, especially now that the company is publicly listed.
SLM Solutions just demonstrated the productivity of its new 12-laser NXG XII 600 PBF system with Porsche. The Porsche advanced powertrain engineering department focuses on large powertrain applications, such as the E-drive housing and cylinder blocks or cylinder heads in additive manufacturing.
Lighter, more rigid, more compact: as reported this morning by 3D printing partner SLM Solutions, Porsche has produced its first complete housing for an electric drive using 3D printing. The 3D printed E-Drive housing on the engine-gearbox unit produced using the additive laser fusion process passed all the quality and stress tests without any problems.
Cadillac’s introduction of the new 2022 CT4-V Blackwing and CT5-V Blackwing will also mark the revival of one of the most popular features for driving enthusiasts – the manual transmission. These manual transmissions were produced using new additive manufacturing applications that will bring 3D-printed parts into the upcoming ultra-high-performance sedans.
General Motors is opening a 15,000-square-foot Additive Industrialization Center, a ground-up facility exclusively dedicated to productionizing 3D printing technology in the automotive industry. The AIC is the capstone of GM’s expertise and increased investment in 3D printing over the last several years.
Every day, industries across the world face unique and interlinking challenges as a result of the COVID-19 crisis. For the automotive industry, it’s a complex picture in which there are both hurdles and opportunities. In this feature, Eric Pallarés, Chief Technology Officer at BCN3D, considers the impact of this tumultuous year on the automotive industry and how additive manufacturing can help.
Sometimes a photo is worth more than a thousand words. This is definitely one of those times: Rolls Royce (part of the BMW Group, one of the most active in implementing AM for production) just showed off a large batch of DfAM optimized and serially 3D printed automotive metal parts.
Larger parts seem to be the trend for metal 3D printing lately. Maybe not yet mass produced large parts but certainly some big one-offs for custom luxury and racing cars. Leveraging the expertise and AM capabilities at AM and engineering services provider MIMO Technick, the Papadakis Racing team built an impressively large 3D printed turbo manifold for it latest racing vehicle.
Leavine Family Racing selected the MakerBot‘s METHOD X 3D printer to leverage MakerBot’s portfolio of materials and advanced thermoplastics available for both rapid prototyping and end-use parts. METHOD’s ability to print at extremely high temperatures was also a benefit for Leavine, which needed materials with high strength and high heat resistance for race parts. The team opted for three MakerBot METHOD X 3D printers, two for the garage and one that could be set up in Leavine’s office or taken on the road for use on-site at races.
Volkswagen purchased two Stratasys J850 printers to enhance its prototyping capabilities and to build new automotive design capabilities into its creative process. The J850 is a powerful tool for car manufacturers because it can accomplish multi-material manufacturing tasks in color. The Volkswagen Pre-Series-Center is 3D printing a wide range of ultra-realistic prototypes for both interior and exterior applications, which helps the company drive further innovation in new vehicle design.
EV truck manufacturers are emerging as leading innovators in manufacturing. After Quantron used VJET X technology to produce an engine housing, Nikola Corporation has now invested in a large-format FFF additive manufacturing system, the BigRep PRO, to streamline the design and manufacturing processes of their zero-emission battery-electric and hydrogen fuel-cell electric vehicles, electric vehicle drivetrains, vehicle components, energy storage systems, and hydrogen station infrastructure.
Over the holidays, I flipped through a book called “21 Lessons from the 21st Century” written by Yuval Noah Harari. The first sentence of the introduction goes like this: “In a world deluged by irrelevant information, clarity is power.”
Czinger, a Los Angeles-based company founded last year by Divergent3D founder Kevin Czinger, has revealed the first details about its first hypercar, the Czinger 21C. Created by “21st century artisans” using additive manufacturing technologies, the innovative hypercar will make its global debut at the upcoming Geneva International Motor Show next month.
The new Lamborghini Sián Roadster has just been unveiled and it looks gorgeous as usual while presenting several new technologies, including 3D printing for extreme customization. Engineered around Lamborghini’s iconic V12 engine with unique hybrid technologies, this open-top hybrid super sports car is intended to offer an anticipation of automative future.
Sterling Backus’ 3D printed Lamborghini was one of 3dpbm’s biggest stories ever and rightly so. The project is truly amazing: to think that someone could 3D print several parts of an Aventador replica’s body at home, on basic desktop systems (used as a base shape for composites), and actually build a working car seemed impossible. And yet, here it is: the (almost) final product looks truly amazing and it is a great inspiration for STEM education, which is exactly what Backus set out to promote.
In yet another example of additive manufacturing in the automotive sector, Chevrolet announced that its 3D printing racing program supported over 80,000 miles of racing. This milestone is indicative of the competitive and manufacturing efficiency derived from AM products. Chevrolet’s announcement pairs with this Network’s recent reporting on Team Penske’s and Oxford Brookes Racing’s implementation of AM parts in their race cars.
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3D printing has found yet another application in the automotive sector. Ding Tool LLC, a company specializing in paintless dent repair tools, is launching a series of 3D printed dent repair tools at the SEMA show this week in Las Vegas. The patent-pending tools were 3D printed using technology and materials from B9Creations, a South Dakota additive manufacturing solutions company.
German automaker Audi has announced it will be expanding the use of polymer 3D printing in its production lines. The technology will be leveraged to produce custom designed auxiliary tools on demand. As part of the expansion, Audi will be establishing a separate department to oversee the integration of polymer AM at its Neckarsulm site.
Debuting at the 2019 Geneva International Motor Show, the Fiat Centoventi Concept represents the brand’s vision of electric mass mobility in the near future. The Fiat Centoventi (Italian for ‘one hundred and twenty’) is based on Fiat’s 120 years of history and experience in the field. In keeping with the brand’s tradition, it is destined to distinguish itself from the pack just like the Fiat 500 did in the 1950s. It sparked an industrial and cultural revolution, going beyond the traditional boundaries in design and engineering to become the first real example of mobility affordable to all.
German automotive manufacturer BMW is rolling out a new M straight-six engine, the BMW S58. The innovative engine, which will replace the S55 engine as the face of the M Division, integrates a number of exciting features including a cylinder head made from a 3D printed core.
The inside mirror base for the Mercedes-Benz 300 SL Coupé (W 198 model series), the spark plug holder from the tool kit of this iconic sports car as well as the sliding sunroof rollers for the W 110, W 111, W 112 and W 123 model series: these are important replacement parts for faithfully maintaining this classic of the brand with the star. They are once again available in genuine quality. Mercedes-Benz Classic has them newly produced in a 3D print. The process is particularly well-suited to smaller quantities and if the genuine tools are no longer available, for example. Mercedes 3D printed spare parts allow gaps in the replacement part supply of classic vehicles to be closed.
Stratasys is furthering its collaboration with Team Penske, a competitive motorsports team that competes in NASCAR, IndyCar and three other racing series. The technical partnership was originally formed in February 2017.
There is no question that additive manufacturing has been a dream technology for restorers of vintage or rare cars. Our latest example of how the two fields have overlapped beautifully is coming from the Goodwood Revival automotive festival, where an ultra-rare, fully restored Alfa Romeo Tipo 33/3 sports car will be on show.
As Formula One becomes more open about the use of AM in its development and production processes, Alfa Romeo Sauber F1 Team has revealed that five new large-format ProX 800 SLA 3D printers from 3D Systems have joined its extensive arsenal of 3D Systems SLS and SLA solutions. In addition, the company is leveraging its experience and capabilities to provide additive manufacturing services and expertise to 3rd parties
