3D Printing for Automotive Parts: What You Need to Know
Newer, better-performing automobiles are in high demand, but the automotive industry must also optimize manufacturing and simplify supply chains and logistics to meet this demand. 3D printing is one technology that is assisting in meeting these issues.
All parts of the car manufacturing process are increasingly looking into 3D printing. This technology is being employed for a variety of purposes, including quick prototyping, tooling, and even the production of finished components.
Here are a few encouraging ways automotive businesses leverage 3D printing to boost production, which is just one of many growing uses for the technology.
The Importance of 3D Printing for the Automobile Sector
For a number of reasons, 3D printing is slowly but surely becoming more popular among car companies. In more ways than one, 3D printing automotive components saves the day with its rapid production and reduced costs. Listed below are just a handful of these advantages:
1. Reduced Lead Times
To stay competitive, the automotive sector is always in need of new developments. With each new product, manufacturers aim to wow buyers with something special. Therefore, extensive prototyping (including design, manufacturing, and testing) is required. Without 3D, it would be very time-consuming to use traditional production techniques for simple prototypes.
Additionally, the production of the specialized tools remains an ongoing requirement even following the prototyping phase. Other methods could significantly reduce output as well. This would add to the production time of the car and could perhaps prevent the manufacturer from enjoying the first-mover advantage. On the other hand, 3D printing makes it possible to create tools or prototypes in a single day! This considerably shortens the time it takes to make individual components.
2. Realistic Concept Designs
The software plan is the initial stage of vehicle design. Just because a design seems good on paper doesn't guarantee it will be successful in production. Now, we may introduce 3D printing to the picture. The method allows the producer to envision design testing in a practical light.
3. Adaptability of the Design
When making cars, the weight is the most important factor in determining the fuel efficiency. To reduce the car's weight, it is necessary to determine the appropriate weight for each component. New opportunities have arisen because of the 3D-printed auto parts. Due to the layered nature of 3D printing, designers may optimize individual layers to create a lightweight vehicle, which in turn reduces fuel consumption.
4. Protects Intellectual Property
The automobile industry places a premium on intellectual property secrecy. Even more so, 3D printing makes this prospect a reality. Owing to the on-site nature of most 3D printing operations, there's little chance of ideas leaking to competitors.
5. Cost
Making a profit relies on producing high-quality cars at the best cost. This necessitates the most effective means by which the producers can control their production costs. The cheap production costs of 3D printing make it a promising tool for this endeavor.
Use of 3D Printing Technology in the Automobile Sector
1) Making Replacement Parts
In fact, the manufacturing company doesn't even make some of the parts that go into making a car. Given the low demand, it's reasonable that these companies would choose not to manufacture some items. It won't change the fact that making these components just lengthens the manufacturing cycle.
However, if you outsource the item to a small-scale 3D business, you can make the parts you require that aren't commonly available. For many, this also represents a new opportunity for business. One option would be to partner with a company like AutoProtoWay to handle the low-volume production and become a distributor for these parts. Although 3D-printed auto parts are still in their infancy, their widespread adoption is inevitable.
2) Rapid Prototyping
The production process for automobiles relies heavily on the creation of prototypes. The real automobile parts could be too expensive to use for the prototypes, though. The procedure would be lengthier due to the need for multiple iterations of the prototypes. 3D printing of auto parts is useful in this regard. Rapid and inexpensive prototyping is possible with 3D printing, in contrast to more conventional methods.
The versatility of quick prototyping has really expanded with the advent of 3D printing. Making a prototype harnessing this technique can take a day at most.
3) Custom Parts and Tools Production
These days, it's not uncommon for customers to personalize their new rides. Manufacturers also create limited editions of automobiles that can include different bespoke parts, in addition to those who upgrade their cars on their own. On the other hand, it may be physically difficult to find the components you need. But other production methods could be time-consuming and expensive compared to 3D printing the necessary auto parts for the custom car.
There are instances when the necessary tools for manufacturing these cars just aren't available. 3D printing also gives producers another option for creating the required fixtures and jigs. Volkswagen is one major company that employs 3D printing to make tools.
3D Printing Materials
a) ABS
The filament that is most commonly used for 3D printing car parts is Acrylonitrile Butadiene Styrene (ABS). Its extensive usage in 3D printing automotive components is not surprising for the reasons stated. It is capable of withstanding temperatures ranging from -20°C to 80°C for long durations. Along with being shock-resistant, it is incredibly flexible. Lastly, it offers superior heat resistance compared to most materials due to its high transition-to-glass temperature.
However, it can warp easily, so it's best to use a 3D printer in a heated bed when dealing with ABS.
Purchase link: Amazon.
b) PLA
Some people may find that the warping of ABS is a problem. Then PLA filament is the second best material for 3D printing auto parts if you fall into that category. PLA won't distort as easily, making it ideal for 3D printers that don't have heated chambers. Its transition temperature to glass is lower than ABS's, but it isn't as shock resistant.
Purchase link: Amazon.
c) PETG
PETG is basically a step up from PLA. It adheres strongly to print beds, sometimes too well. However, using a heated bed is recommended to ensure proper adhesion and prevent warping. It outperforms many other filaments in terms of heat and shock resistance. Its price is comparable to PLA as well.
Purchase link: Amazon.
The High-Performance Mustang Shelby GT500 Parts 3D Printed by Ford
Complete case study: fordmedia
Thirty years ago, Ford Motor Company bought the third 3D printer ever produced, making them one of the first adopters of 3D printing.
Aiming to include 3D printing into their product development cycle, Ford has taken measures since opening their Advanced Manufacturing Centre last year. The next step for the business is to find ways to implement the technology in their manufacturing processes.
The 2020 Shelby GT500, its newest model, is a prime illustration of this. The 2020 Shelby GT500, the most aerodynamically enhanced Mustang to date, is supposedly going on sale later this year. Conducting virtual design testing was an integral aspect of developing the blueprints for the high-performance vehicle. The crew was able to accomplish its downforce, braking, and cooling goals by conducting virtual tests on over 500 aerodynamic and cooling 3D designs.
Following the identification of the most promising concepts, the engineering team at Ford utilized 3D printing to fabricate and evaluate prototypes. As an example, the group was able to print and test ten different designs for front splitter wickers all at once and then send them out for evaluation.
Two structural brake components for the 2020 Shelby GT500 will be 3D-printed, in addition to 3D-printed prototypes used for design validation and functional testing. Printed using Carbon's Digital Light Synthesis (DLS) 3D printing technique and EPX (epoxy) 82 material, these parts have met and exceeded all of Ford's stringent performance specifications.
Ford is clearly setting the stage for accomplishing some pretty remarkable things with additive manufacturing in these applications. In a recent interview with AMFG's Expert Interview series, Harold Sears, Ford's Technical Leader of AM Technologies, emphasized that additive manufacturing will remain deeply integrated into the company's daily operations. "It will become the customary way of doing things, rather than the exception to the rule."
In the future, it will be fascinating to observe how Ford keeps improving vehicle production with the help of 3D printing.
Best 3D Printing Software for Creating Automative Parts
There are many 3D design software available that you can use to prepare your designs for 3D printing, and a good example is SelfCAD. It is a powerful 3D modeling software that you can use to create 3D models from scratch or edit existing designs and customize them based on your needs.
After preparing your files, you can use the built-in online slicer of the software to slice your files and generate the G-code to send to your 3D printer.
In addition to being easy to use, SelfCAD also comes with many resources to help you get started effortlessly. There are many interactive tutorials to help you learn by actually creating 3D models. The 3D modeling 101 series and 3D modeling for beginners videos on YouTube are also great resources to help you learn how SelfCAD works and how you can use it to create your 3D models.
Streamlining Production With 3D Printing
We have only covered 3D-printed auto parts and components thus far. Could an entire vehicle be 3D printed? A lot of people have done it before you, so it's definitely doable. Because they are capable of printing from a wide variety of materials, 3D printers have the potential to make just about anything. The idea of 3D printing an entire automobile using a mix of metals, polymers, and carbon fibre is simple enough to picture.
3D printing isn't perfect, but it helps with the electrical parts, tires, engine, and suspension. Purchasing and installing those parts into a car that is otherwise entirely 3D-printed would be the easier option for the time being.
Enjoy powerful modeling, rendering, and 3D printing tools without the steep learning curve.
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