metal 3d printing is leading the innovations in motor sport · 2019-11-22 · lübeck, germany...
TRANSCRIPT
Metal 3D printing is leading the innovations in motor sport
Dipl.-Ing. Ralf FrohwerkGlobal Head of Business Development
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3D metal printed brake caliper out of titanium
3D metal printed brake caliper out of titaniumThe Chiron is the most powerful, fastest and exclusive production super sports car
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Built on SLM500 Quad Build time: 45hNo of Layers: 2213
The largest functional component 3D printed out of titanium. Ti6Al4V (Grade23)
Tensile strength: 1250 N/mm2Dimensions: 41 cm x 21 cm x 13.6 cm 2 kg lighter than its 4.9 kg machined aluminum counterpart.
Project in cooperation of:
Functional - Test:From 375 to 80 Km/hBreak pressure : 110 barBreak disc temp.: 1100 °C
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SLM applications are well known in the automotive market
Lübeck, Germany
Detroit
Singapore
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SLM Solutions: Leading provider of metal based -Selective Laser Melting „3D printing“ machines
Headquarters
Distribution partners
SLM Solutions – Subsidiary
Shanghai
Moscow
Bangalore
§ > 500 SLM machines installed globally
§ > 420 employees global
§ Global presence in 43 countries
MilanParis
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The new Headquarter - Grand Opening August 24, 2018
7.000m² Office Space
17.000m² Production-, R&D-, Application- and Logistic Space,
MEDICALDENTALAEROSPACEAUTOMOTIVETOOLINGENERGY
SLM Solutions Group is already operating in key industries
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Selective Laser MeltingTechnology & Process
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Powder bed fusion: Selective Laser Melting (SLM) cyclic-process
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Finish part with supportstructure welded on the
substrate plate
Selective Laser Melting with Metal Powder
Aluminum Alloys
Stainless and Tool Steels
Nickel-Based Alloys Titanium Alloys Cobalt Alloys Copper Alloys
Invar 36®
AlSi7Mg
AlSi9Cu3
1.4542 (17-4PH)
1.4545 (15-5PH)
1.2344 (H 13)
1.4404 (316L)
1.2709
HX (2.4665)
IN939
IN718
IN625
TA15
Ti6Al4V Grade 23
Pure Titanium (Gd. II)
SLM® Medi-Dent
CoCr28Mo6 CuSn10 BronzeAlSi10Mg
Qualified Material SolutionsPowder experts are always developing new alloys optimized for selective laser melting
CuNi2SiCr
Selective Laser Melting Machines
SLM®125 SLM®280 SLM®500 SLM®800
Build Envelope 125 x 125 x 125 mm4.9 x 4.9 x 4.9 in
280 x 280 x 365 mm11 x 11 x 14 in
500 x 280 x 365 mm19.7 x 11 x 4 in
500 x 280 x 850 mm19.7 x 11 x 33 in
Laser Configurations
Single (1x 400W) Single (1x 400W / 700W)Twin (2x 400W / 700W)Dual (1x 700W & 1x 1000W)
Twin (2x 400W / 700W)Quad (4x 400W / 700W)
Quad (4x 400W / 700W)
Build Rate up to 25cm3/h up to 55cm3/h up to 171cm3/h up to 171cm3/h
Optical Design for multiple QUAD production
Fibre laser 4 x 400W
SM „Gaus“ Profile
3D Scan-Optic without F-Theta
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SLM 500HL - Quad Scan-Head (clone and independent)
Overlap areas with the same high density and mechanical propertiescompared to single scanner/laser area?
YES!
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Case StudyAutomotive
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Automotive Applications
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Hydraulic control unit from a CVT transmission Comparison: Die cast vs. SLM process
Material: Aluminum AlloyWeight: 930gBuild Time: 19h 25minSurface RoughnessSurface Flatness < 0,4Tolerances < +/- 0,2 X-Ray AnalysisDensityHardness Tensile Strength
Built on SLM 280 - Twin
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Hydraulic control unit from a CVT transmission Durability test
Completed with a machined and preassembled hydraulic control unit and tested in a CVT transmissionThis test represents the life time of the transmission in the car, 60.000km on a test benchTest cycle: 10 - 120°C, 6 wks. 24h/day
After the test, the part was dimensionally and functionally OK
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Automotive: Gear Housing – Potential for innovative design
Material: AlSi10MgWeight: 3920 g / Volume: 1452 cm³ Build Time: 3d 10h 56 min (2pc) – 50µmNumber of Slices: 6090Weight Optimization of 30 %
Built on SLM 500 - Quad
Engine Block Bracket`s – Porsche 911Material: AlSi10MgWeight: 1340 g / pc.Weight Optimization: 20 % Due to lattice structure design!
Built on SLM 500 - Quad
Cooperation Project:
“Haldex” – Housing and Bracket of Front-Axis-Differential
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Current 2 piece designTotal Weight: 2,328 Kg1,890 Kg Housing and 0,438 Kg Bracket
New 1 piece designTotal weight: 1,171 Kg
Built on SLM 280 - Single
- 50,3 %
Material: AlSi10MgBuild Time: 56h (2 pc)
Topology OptimizationBionic - Design
Automotive: Exhaust pipes Material: NiCr22Mo9Nb - Inconel 625
Automotive: Turbocharger Material: AlSi10Mg3
Design and Function Optimizationdue to SLM Process!
Built on SLM 280 - Twin
Automotive Project:
contact: [email protected]
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Automotive: Porsche 991/Carrera – GTS – Targa
Components:
Intercoolers: AlSi10Mg - SLM 500
Intake Manifold: AlSi10Mg - SLM 500
Turbo Chargers: CNC Machined
Inlet Tubes: CNC Bent
Exhaust Manifolds: Inconel 625 -SLM 280
Exhaust Downpipes: Inconel 625 - SLM 280
Exhaust Tips: Haynes 282 - SLM 280
SLM technology drive up the Power HP up from 370 to 660
(WHP, measured at tires on rollers)
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Exhaust – Tail pipe set
Automotive: Material: Steel 316lLayer thickness: 50µmBuild time: 45h – 1 set.Post processing: Sandblast and
Barrel finishing
Built on: SLM 280 Single
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Aftermarket part:Front - timing cover – „Cadillac Eldorado“ – Modell 1967
Damaged Front timing cover !
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Aftermarket part:Front - timing cover – „Cadillac Eldorado“ – Modell 1967
Gom – Scanner operationTime: 2 h
CAD – re – modelling of the timing cover into the original versionTime: 19 h (one time action !)
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Printing of new re-designed coverMaterial: AlSi10MgWeight: 2,32 Kg (3,98 Kg with supports)Build Time on SLM280 Twin: 42 h
Post processing:Time to removing support: 3 h Time for surface machining: 10 h
Total time for 1.piece: 76 hTotal time for further production: 55 h
Aftermarket part:Front - timing cover – „Cadillac Eldorado“ – Modell 1967
Printed engine project:
• Printed parts:• CylinderHead• Cylinder• Crankshafthousing-right& leftside• Clutchcover• Cam Cover• Stearingcover• Oilfiltercover• Oilpump cover
• The goal of the project was to test the technology for the future usage
First global 3D printed Formula Student Race Engine
SLM Solutions Group AG company presentation – 5. Automotive AM Conference – Munich May 07&08.2019 – Ralf Frohwerk
+32 %
+25 %
SZEngine EVO6:
• Increased stroke: 72 à 76 mm
• Change fuel to ethanol
• Increased compression ratio: 13,5 à 15,5
• Modified intake cam profile
First global 3D printed Formula Student Race Engine
SLM Solutions Group AG company presentation – 5. Automotive AM Conference – Munich May 07&08.2019 – Ralf Frohwerk
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First global 3D printed Formula Student Race Engine
Future plans:
• Further work with the cylinder head• Different designs for the test bench and
the races• Possibility to work with different intake
port designs
• First prototype of the Crankshaft• Find the most ideally position for the
balancing weight with the lightest design
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Automotive: F1 – Lower Winglets
Established in 1983, specialising in
Additive Manufacturing &
Precision Engineering
35 Years of Prototyping Excellence
• Additive Manufacturing
• Precision CNC Machining
• Vacuum Casting
• Specialist Model Making
365 mm
192
mm
§ Material: AlSi10Mg § Part weight: 0,450 Kg
§ 0.5mm wall thickness with printed internal structure for strength and stability
§ Fins “hollowed” out for weight optimisation
§ Finished component with additional polishing
Manufacturing time:STL Preparation 4 hrsPrinting Process 11 hrsRemove Supports 1 hrPolishing Features 48 hrsTotal Time 64 hrs
Build on SLM 500 Quad
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Automotive - Cylinder Head Project
Built on SLM 500HL- Quad
Material: AlSi10MgBuild time: 5 days + 5h (125h)
SLM Part in Series Production for Chiron !
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- Motor Bracket with integrated cooling channel
- Supplier:
- SOP - Start of Production (of the SLM part): May 2016- Material: AlSi10Mg- Build on: SLM 280 Twin
The world's most powerful road car with 1500 Ps !
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Cam Cover for Chiron, build on SLM 800!
Material: AlSi10 MgLayerthickness: 60 µmBuild Time: 4d 7h 42minFull loaded: 8 pcWeight: app. 2,5 Kg/ pc
Under Development:To build the part with 90µmBuild time reduction app. 20%
735
mm
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The World`s first 3D Printed Super Car !
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The 3D-printed ‘Blade'
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Blade Chassis Assembly Video
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The 3D-printed ‘Blade' - Los Angeles Auto Show
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Honda Monkey – Jane Design Concept
Material: AlSi10Mg Design optimization in function and weight !
Mudgard:SLM 500 Quad
430 g - 14h
Luggage Rack:SLM 500 Quad
1175 g - 18h
Brake & Clutch Levers:SLM 280 Twin
52 & 57 g - 3h / setPetrol - Tank:
SLM 800 Quad3280 g - 27h
Gauge Bracket:SLM 280 Twin
110 g - 3h
www.slm-solutions.com
Thank you for listening!
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