Additive manufacturing(AM) - or 3D printing as it is also called –is said to be a game changer for the automobile industry in the near future. 3D printing had been hailed as disruptive technology when it was first introduced, however it was the automobile sector and the aerospace sector were amongst the first to its real potential.
The automobile industry is always on the prowl for new technologies that would help them ramp up production. And it is not only the traditional automakers and OEMs (Original Equipment Manufacturers) that use 3D printing; it is custom and luxury car makers as well. In fact, as we will see later in the article, it is the custom and luxury car manufacturer who stand to gain the most out of 3D printing for the benefits the technology offers. And EV manufacturers - the latest entrants in the automobile sector – are gainfully using AM too.
A bit about 3D Printing Manufacturing processes have seen a lot of innovation in this industrial age. Computer Numerical Control (CNC) machine tools that could be used for mass manufacturing were introduced in the late 1960s. Because they chipped away at material, they were called subtractive manufacturing processes. As PCs grew powerful, they ushered in a new way of printing objects / parts with the help of CAD files and appropriate software. Called as Additive Manufacturing or 3D printing, this technology allowed layer by layer printing of objects using output from CAD files. Since they were precise, 3D Printers allowed intricate shapes to be printed. In addition, the parts produced by 3D printing technology were lighter than those manufactured traditionally, a characteristic that was quickly encashed by the automobile and the aerospace industry.
3D Printing in Automobile Sector
Automotive additive printing enables the production of components without the need for tools, thereby cutting development and production costs. The parts can be installed directly in serial production vehicles, reducing assembly time. While 3D printing today includes plastic, metal and ceramics, the automobile sector uses 3D printing technology extensively for plastic parts that are intricate to manufacture because they have complex geometries. Hollow auto parts are made by using an internal scaffolding method, which is removed after moulding. While there are many 3D printing technologies available today like Stereolithography (SLA), Digital Light Processing (DLP), Selective Laser Sintering (SLS), Material Jetting (MJ), Laminated Object Manufacturing (LOM), and others, it is the Fused Deposition Modeling (FDM) that is used extensively in the automobile sector. FDM technology was invented by Stratasys founder Scott Crump, and Stratasys is still the leader in manufacturing of world class 3D Printers. FDM Technology works with specialized 3D Printers and production-grade thermoplastics to build strong, accurate, durable and dimensionally stable parts.
Benefits of 3D Printing for Automotive Sector
Iterative R&D
There is an increasing pressure on OEMS and automobile manufacturers to innovate faster. They need to shorten the production cycle in order to ensure that their innovations are still up-to-date when a new model reaches the market. A crucial aspect of R&D in any auto company is that of prototyping - be it that of a new component or a new model altogether. Using traditional way of manufacturing, it takes weeks or even months to come out with a prototype, a delay that auto makers cannot afford today. 3D printing has reduced that period quite sharply, thanks to direct printing.
Reduction in weight of components
In any auto company, it is an ongoing challenge to reduce part weight without sacrificing structural strength. Any reduction in part weight leads directly to an increase in fuel efficiency. It is possible to perform part alterations at a structural level using additive manufacturing. Coupled with advanced simulation and modelling software like Altair Inspire™ Print3D, HyperWorks, Radioss™, MotionSolve™, PTC Creo and other such software, manufacturers and OEMs can deliver parts that equal or greater performance with the use of less material.
Efficient Management of Supply Chain
Most volume car manufacturers use just-in-time manufacturing (very similar to lean manufacturing), where large quantities of parts arrive at the production line immediately before assembly to reduce the need for costly warehouse space. AM can facilitate this process of creating production parts on-site, should there be disruptions to a manufacturer’s supply chain.Parts that are manufactured using 3D printing include ducts and brackets, gear lever and pedals, brake rotors, radar antennae, and other such parts.
Custom Car Manufacturing
While prototyping remains the primary application of 3D printing within the automotive industry, using the technology for tooling is rapidly catching on. Luxury car manufacturers do not bulk manufacture their top-end or limited edition models. For such manufacturers, 3D printing has proven to be a boon. Custom jigs, fixtures, tools,seats, cast aluminum wheels, and many other interior parts of a car are now regularly 3D printed. Another application of 3D printing for the automotive sector is the printing of parts for vintage models. Porsche is one such example of high end auto maker that leverages 3D printing.
Redefining the EV
As compared to vehicles that run on internal combustion engine (the traditional 2 - 4 wheelers), an electric vehicle (EV) is less complicated. The powertrain of an EV is simple, and in general a EV has less number of body parts. Since 3D printed parts can be made light weight thanks to modelling and simulation software like that from PTC and Altair, it will help increase battery life. As 3D printing manufacturers offer more and more choice of printing material, it will help EV manufacturers to try various combinations with optimal properties. In addition, 3D printing and digital inventories will help ramp-up EV production.
In summary, automobile manufacturers today are under increasing pressure to deliver better models with superior mileage in less time. 3D printing helps develop faster prototypes, accelerating the development process. Custom and luxury car manufacturers benefit from AM as they can produce custom parts at lesser cost as compared to traditional tooling. EVs benefit as lighter parts translate into better battery life and consequently longer travelling range. As more and more innovative 3D printing material is introduced, and as printers improve technologically and begin to cost less, the automobile sector is all set to reap the benefits of AM technology.