Why 3D Printing in Automotive

Beyond Prototyping

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Gartner’s 3DP Hype Cycle - 2017

2
Source: Gartner
Materialise Today
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OFFICES PRODUCTION CENTER COMPETENCE CENTER

Materialise Core Business

Materialise offers software and services that form the

backbone of the Additive Manufacturing eco-system.

Our solutions are open and neutral, allowing all

players to better manage the 3D printing process and
build more meaningful 3D printing applications.

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Three Core Competences

3D PRINTING ENGINEERING

SOFTWARE
DEVELOPMENT

Date | Firstname Lastname | 6

Creating innovation and competitive
advantage across industries

Materialise Materialise Materialise

Software Manufacturing Medical

Managing of complete Certified end parts Image-based planning

3D printing processes manufacturing and 3D printing

Getting the most out of Patient-specific guides

Prototyping
3D printing machines and implants

Design and data

Design and engineering Engineering on Anatomy
preparation for 3D printing
 Co-Creation

LEARN CREATE FIND

3DP ACADEMY
In a full-day program our experts inform you on the strengths
and weaknesses of the most relevant technologies and
materials. Furthermore we share best practices in design &
engineering and analyze a number of groundbreaking AM
cases.
GOAL:
Get your team up to date on all things AM
CO-CREATION LAB
The Materialise CO-CREATION LAB is an interactive session in
which experts from your company join forces with ours. The
result is a multidisciplinary dream team that will unlock the
hidden potential of 3D Printing in your company.
GOAL:
Create innovative concepts for your market
3DP SCAN
The 3DP SCAN is an AM audit, held at your premises. A
Materialise AM consultant will look for potential applications
on the spot and provide you with a full report afterwards.
GOAL:
Spot parts that can benefit from AM
Our Partners

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AM – Industry
Adoption & Challenges
Current Applications and Future Potential of
3DP by Industry

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Source: EY
 Barriers to Implement

BAAM (upto 6 m x 1m x 0.75m build platform) -

Cincinnati Industries and Oak Ridge National Lab

EBAM (upto 5.8m x 1.2m x 1.2m build platform) - Sciaky

Mammoth SLA m/c (2.1m x 0.8m x 0.7m) - Materialise

Greater co-operation with service providers

In-process QC tools

3rd party material vendors

Automation, integration and continuous production

technologies

Redesign for AM mindset growing

Source: EY 12
 Optimization in next gen AM systems

13
Source: Roland Berger
Innovations Across the Entire AM Process Chain

Source: Roland Berger 14

 Hybrid Systems

Higher build rates

Lower manufacturing costs

Large build chambers

Both laser powder bed and

powder feed with 5-axis CNC
milling possible

Source: Roland Berger 15

Automation Concept

Manual Unloading Automated Unloading

- (build set-up and process monitoring)

Source: Roland Berger 16

 Integration Concept

High productivity by
continuous production (2
build chambers)

Integrated post-
processing (HT) increases
process stability and
product quality

Automated handling

Instant switching between

multi materials gives high
flexibility

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Source: Roland Berger
 Material Costs (metal only)

OEMs offer material specific

parameter sets and powder
quality control

Must weigh –

initial implementation speed and

reliability

vs.

higher cost and lock-in effect

18
Source: Roland Berger
 Post-processing Costs

Highly part dependent

Must be factored in while evaluating

overall costs for AM

Could be avoided to some extent

during design for AM stage

19
Source: Roland Berger
Prototyping to
Manufacturing ?
Evolution of 3DP Applications

To most companies: AM ~ Rapid Prototyping

Future (and growth potential) lies with Direct Manufacturing

For full impact, AM must be used in Serial Production for end-

use products

38% of companies expect to use 3DP for production of end-use

parts by 2021

Germany is most conservative (25%)

China/S. Korea are most optimistic (50%)

21 Source: EY
From prototyping towards manufacturing

Rapid prototyping is well established

Transition to manufacturing, new

Rapid Prototyping
challenges arise 34%

Laborious process Rapid Manufacturing 34%

14%

16%
2%

Early Early
Pioneers Late Majority Laggards
Adopters Majority 22
Manufacturing requirements

Standardization

Monitoring and logging

One integrated solution

Open platform

Allows R&D

Repeatable quality
Pre-build In-build Post-build
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Quality Management Goals

Repeatability

Accuracy

Traceability

Sustainability
Repeatability Accuracy Repeatability and accuracy
Compliance

Efficiency
Manufacturing costs
Part costs in M3DP primarily depend on
The melted volume and not the complexity
Size part / build height
Material & finishing
Part orientation

Reduction of part volume leads to reduced costs

Hollow structures
Lightweight structures
Thin walls
 Proto Time Reduction – across industry

27
Source: EY
 Proto Cost Reduction – across industry

28
Source: EY
Core Functions expected to be benefited by 3DP

29
Source: EY
 3DP Expectations by Industry – Next 5 years

30
Source: EY
Additive Manufacturing
Solutions for the
Automotive Industry
Applications of AM in an Automobile

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Prototyping
Prototyping for the Automotive Industry
Design verification

Form, Fit & Function testing

Scale models and concepts

Lear Automotive Car Seat Frames

• Customer needs: better alternative for sheet metal

prototypes
• Faster
• Less expensive
• More representative
• More reliable during testing phase

• Materialise solution: metal plated prototypes

• Mammoth stereolithography components with
metal lamination of copper and nickel
Ossa Show Model

 Customer needs: Famous Ossa brand needs show vehicle

 To present the rebirth of the Ossa at the Milan Motorcycle Show
 To show and explain their new motorcycle concept : design and
position of chassis, engine, fuel tank, etc.

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Ossa Show Model

• Materialise solution:
• Complete bodywork exists of stereolithography and laser sintering
components, assembled and finished by the customer
• From files to products in 10 days
Sintered fuel
tank plug
Stereolithography
bodywork & covers
Sintered fender
support
Sintered swing arm

Sintered clutch Sintered cylinder

cover and cylinder head
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R&D
Optimized Pressure Valve
From Traditional Design to Metal 3D Printing
Optimized Pressure Valve

Traditional Valve

straight and circular drillings

auxiliary drillings that need to be plugged afterwards

(risk of leakage)

initial weight: 2.5kg

Optimized Pressure Valve

Meshing Optimization 1st Simulation

Hypermesh OptiStruct OptiStruct

Remeshing
Surface data
3-maticSTL

Manufacturing Analysis
SLM Solutions Hyperworks
Optimized Pressure Valve

600g of mass compared to the original 2.5kg (74% lower)

No need for auxiliary drillings, less chance of leakage

Improved flow because of smooth transitions between the internal channels

The time from optimization to final design was greatly reduced by working
immediately on the TO data with 3-maticSTL
Altair brake pedal : TO + Texturing

• Altair topology optimization software reduces the

volume of object, without compromising strength.

• In past they applied this technique to lower down

weight of a race car brake pedal.

• However re-designing organic models at CAD level

can be time consuming and difficult job.

• But with 3-matic, it is very easy to do design

modification at STL level.

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Altair brake pedal : TO + Texturing
3-matic was further used to-

 Add thickness at thin sections

 Rim designing

 To apply a functional texture to improve the grip

Final outcomes-
20% lighter with same strength

Less production time, no tooling required

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Toyota car seat: TO + LWS
Toyota Central R&D labs wanted to create a car seat with minimal volume &
optimal heat capacity.

They have a topology optimized part. We incorporated LWS to make it more

lighter.

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 Toyota car seat: TO + LWS

The input received from Toyota is a model containing high density & low density areas.

To populate low density areas, we developed a new unit cell (truncated octahedron),
that allows more heat flow.

A pattern of elastic beams were added at edges to increase the comfort.

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Toyota car seat: TO + LWS
After all these modifications, we cut the seat into 2 parts using our STL editor Magics, with dowel
connections.

Needless to say, the outcome was a 250 GB STL file, it was processed by ourbuild processor
technology (resulting into 36MB) and finally sent to machine for printing.

Final result:-

Weight from 21.6 kg to 6.3 kg

Heat capacity from 35.4 J/K to 14.5 J/K

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Robirds – ensuring human safety
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 3D printing used for design freedom
and production optimization

Laser Sintering process

Glass-filled polyamide

All internal fixation points for mechanical components directly printed inside the body

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Catalytic part for Bosal
Supporting the Research Phase of
Product Development
Catalytic part for Bosal
to reduce exhaust gas pollutants

Original Production Process

Part design Milling Turning Welding

“We consistently choose Materialise

because Materialise is easy to do business with.”
With Metal 3D Printing — Bosal

Part design Production

Small-Series Production
(OR)
One-Off End-Use Parts
InMotion Electric Race Car
Titanium Wishbones for Suspension
InMotion Race Car: Titanium Wishbones

Wishbones for the suspension

of an electric race car, printed
in titanium
InMotion Race Car: Titanium Wishbones

Requirements
No internal
support structures

Technology
Metal 3D Printing

Material
Titanium (TiAl6V4)

Finishing
n/a
InMotion Race Car: Titanium Wishbones

Manufacturing Post machining Assembly

From CAD to assembly in 10 days

Date | Firstname Lastname |
World Solar Challenge

Hold 432 Lithium-ion cells

Co-creation with Materialise

D&E team

Modular open frame design to

ensure optimal air flow for
cooling

Honeycomb structure to reduce

weight while keeping a strong
structure

Date | Firstname Lastname |

Date | Firstname Lastname |
3-D Printed Upgrade
Upgrade designs

Customise parts

Zero tooling investment

Seat, housing for display screen,

front and rear indicators, iconic
detachable headlight

Lighter bike that’s faster and more

cost-effective to manufacture

“I believe that 3D Printing is the future. I can imagine the Bicicletto in

10-15 years, completely prototyped and produced with 3D Printing.”
- Mr. Juliano Imprescia, Nuova SPA’s CEO
Date | Firstname Lastname |
Jun Race Car
Textured Steering Wheel
Textured Steering Wheel for June Race Car

Requirements
Functionality, textures,
cost-effectiveness

Technology
Laser Sintering

Material
PA

Finishing
Color Dyed
Date | Firstname Lastname |
 Open Structure Mobility Concept

Challenge - create a light but safe car, avoiding mold creation, allowing mass customization

Combine different car body designs on a small standardized platform

Optimized structures to reduce weight but maintain stability

Date | Firstname Lastname |

Optimization of car frame design

Smoothen and redesign TO design on STL level

Lightweight structures in pillars

Optimization of car seat design

Lightweight lattice structures

Scale and readjust beam thickness Date | Firstname Lastname |

Concept Cars
Sintesi Concept Car
Stereolithography components
Parts for Pininfarina Sintesi Concept Car

Requirements
Customized design;
complexity, functionality

Technology
Stereolithography

Material
Poly1500

Finishing
Translucent
Production Tools
Production Tools for the Automotive Industry
Jigs

Fixtures

Assembly aids
Production Tools for the Automotive Industry

Highly customizable

Allow complex internal and external geometries

Light and modular

Fast and economical modification

RapidFit Automotive Fixtures
Locators for Customized Fixtures
Locators for RapidFit Custom Fixtures

Integrated Functionality

Flexibility
Speed
Customization
Cost
Modularity
Complexity
Precision
Locators for RapidFit Custom Fixtures

Requirements
Integrated
functionality

Technology
Laser Sintering

Material
PA

Finishing
Painted
Volvo Jig
Logo Gluing Jig
Goals, Solutions, Results

Lightweight gluing jig that ensures accuracy and

repeatability, while protecting the paintwork

PA connectors with integrated 0.2mm accuracy

Reduce weight
gluing channels
64% weight reduction
Increase the accuracy
PC-ABS Pads - covered with
leather 48% cost reduction
Decrease cost and lead time
Milled positioning points (POM) 67% lead time reduction
Volvo Gluing Jig
Solution
PA connectors with integrated
gluing channels
PC-ABS Pads - covered
with leather
Milled positioning points (POM)
Technology
Laser Sintering
Fused Deposition Modeling

Material
PA
PC-ABS
Carbon Tubes

Finishing
Color Dyeing
Assembly
Spare Parts
Mercedes 300 SL
Re-Engineered Instrument Backlight Panel
Instrument Panel Backlights by ClassicTacho

Requirements
Re-Engineered
Spare Part

Technology
Laser Sintering
Vacuum Casting

Material
PA, HMPU13

Finishing
Color Dyed
Image credits: Mercedes 300 SL Cabrio by DOMINIK BARTSCH is
licensed under CC 2.0
Spare Parts for the Automotive Industry
Re-engineering allows for function integration

Cost-effective small series production

On-demand (no stock risks)

Additive
Manufacturing
Solutions for
Production Lines
 Production Tool Applications

Casting Vibratory
Fixtures
Patterns Feeders

Quality Control
Brackets
Aids

Jigs and
Nozzles Grippers
Working Aids
How additive manufacturing can help

Component
Supply Chain Innovation
Performance

Reduce Weight Reduce Lead Times Shorten Time to Market

Improve Air or Liquid Flow Meet Handling

Reduce Costs
Requirements

Facilitate New Product

Increase Product Quality Reduce Stock
Introduction
Nozzles

Optimise flow of air, gas or liquid

Complex or intricate designs

Cost efficient small series

End-product innovation
Flexible Grippers

Improved gripping

Flexible material

Delicate products

Different shapes

Customizable
Vacuum Grippers

Complex shapes

Lighter and faster

Integrated channels

Customizable

Less assembly
Finding your applications

Component
Cycle Time
Identify the main challenges Performance

Locate your problem areas

Efficiency &
Product Quality
Productivity
- Long lead times

- High failure rate

Health and New Product
- Complex parts Safety Development

Could another design and technology solve this?

Sample News Clips (2016-17)
– AM in Automotive

Audi

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Conclusion

Way we manufacture products for automotive is changing, not just protos.

Critical to identify the right application for AM in automotive and manage

‘benefit expectations’

AM mindset adoption and AM application specific know-how is key

Via partnerships

Via right investments

90
Come join us in
turning future into
present!