3D Printing in automotive industry

3D printing in automotive industry

Usage of 3D printing is popular in automotive industry, in which it is used for manufacturing prototypes as well as finished parts. For example, car manufacturer Koenigsegg uses 3D printing to manufacture the variable turbocharger for their One:1 model. The model has one on one power/mass ratio (HP/Kg). The fully metal parts are lightweight and endure high temperatures and racetrack conditions demanded from hypercar. Also some Formula 1 racing teams used 3D printing for prototyping, testing and ultimately, creating custom car parts that are used in competitive races.

Metal 3D printing enables manufacturing of high quality parts with complex structure, lightweight composition and endurance of high temperature.

3D Printing multifunctionality: Structures with electronics

NASA tested power of 3D printing while developing the next generation space exploration vehicle, a CybeSat Trailblazer was launched in November 2013 that integrated 3D-printed stuctures with embedded electronics. Space provided perfect testing enviroment for durability of 3d-printed devices with radiation, low pressure and extreme temperature ranges.

"Based on the best fabrication technology at the time for 3D-printed electronics, stereolithography (SL), a vat photopolymerization technology, was used to fabricate the dielectric structure, while conductive inks were dispensed in channels to provide the electrical interconnect between components. In spite of the structure passing qualification—including temperature cycling, shock and vibration, and outgas testing—the photocurable materials used in SL do not provide the level of durability required for long-term functionality."  

They are trying to address these challenges by developing next generation machine that uses multiple technologies to produce 3D, multi-material, multifunctional devices.

Interesting products/concepts for 3D-printing

1. PCB manufacturing/prototyping

2. Prosthesis

3. Product that is printed and sold as kit e.g headphone kit that includes all electronics and ear cushions. Rest of the parts can be printed locally or printed at home. End product is easy to fix and customizable.

Links to related articles:

http://www.machinedesign.com/3d-printing/who-s-who-3d-printing-electronics

http://www.ams3d.co.za/3dprinter.html

https://www.eos.info/press/customer_case_studies/climbing_shoe

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