How high-performance material 3D printing is applied to the small batch production of terminal parts

High-performance engineering plastics such as ULTEM™, PEI, PAEK and PPSU have significant advantages in terms of lightweight, thermal insulation, electrical insulation, and durability. In many cases, they can become more economical and efficient alternatives to metal alloys. Taste.High-performance engineering plastics based on material extrusion process3D printingTechnology brings low-cost and lightweight solutions to industrial manufacturing applications in terms of design and implementation of customization and small-batch production. This has been verified in the field of formula car manufacturing.

In this issue, we will share application examples of additive manufacturing of lightweight parts for Formula E racing cars, and use these applications to provide a perspective on high-performance engineering plastics.3D printingHow does the technology realize the small-batch production of lightweight terminal parts.

E0711-11 EVO, the Formula E racing car, made a new appearance, using high-performance engineering plastics in large quantities3D printingParts.

From final parts to spare parts

GreenTeam, the student formula electric racing team from the University of Stuttgart, Germany, released the latest model E0711-11 EVO before the upcoming new season. EVO used to be a record-breaking car in the Stuttgart area. The E0711-11 EVO is named after this and represents their vision for the new season. GreenTeam has high hopes for EVO and put a lot of energy into it. “In the past two years, we have re-tailored almost all components for EVO,” said Karsten Müller, who is in charge of vehicle management.The team members have developed a new wheel assembly that provides more degrees of freedom from the perspective of aerodynamics and kinematics. The formula car uses a lightweight design of carbon fiber wheels, new brake calipers, and3D printingThe parts are applied to the body system.

Diverse3D printingapplication

3D printingThe parts are used in different positions on the new electric racing car. About 99 parts of E0711-11 EVO use INTAMSYS-FUNMAT HT. 3D printingEquipment manufactured.3D printingThis makes the manufacturing of parts much faster than traditional manufacturing. In order to better prepare for the new season, there are still many parts on the car.3D printingUsed as a spare part so that parts can be replaced quickly in the event.

FUNMAT HT equipment3D printingVarious racing parts

E0711-11 EVO is the first one developed by GreenTeam with so many high-performance engineering plastics3D printingParts of the racing car.3D printingCompared with machined parts, plastic parts can reduce the weight of the race car by 50%.

With sufficient mechanical properties, these high-performance materials can be used in racing cars.and3D printingProvides the ability to quickly and cost-effectively modify component design, components can be printed on demand, with low cost and short delivery time. In addition, plastic parts also have non-conductive characteristics, which are more popular in the manufacture of electric racing cars than metal parts.

Lighter, faster, and cheaper

INTAMSYS-Yuanzhu Intelligent provides FUNMAT HT for the GreenTeam team 3D printingMachine, INTAM™ cable and new racing car3D printingConsultation on application.

ULTEM™ 9085 material3D printingHigh voltage battery system bus

3D printingComponents are reflected in their new electric racing battery system, braking system and power electronics. E0711-11 EVO must withstand extreme conditions in the race. The use of high-performance engineering plastics can meet excellent mechanical properties and high chemical resistance. Performance, good flame retardancy and high strength-to-weight ratio are required.

ULTEM™ 1010 material3D printingCustom gasket

ULTEM™ 9085 for GreenTeam 3D printingThe bus bar of the high-voltage battery system. ULTEM™ 9085 material has the characteristics of high performance, chemical resistance, thermal stability, etc., and can be used as a substitute for metal parts.Compared with previously machined parts, use high-performance materials3D printingThe parts have reduced the weight of the car a lot. INTAMSYS FUNMAT HT 3D printingThe equipment is designed for PEEK, ULTEM and other high-performance materials3D printingThe design also supports engineering plastics such as PA, PC and ABS. Parts printed with high heat-resistant materials such as PEEK, PPSU or ULTEM are used to make real parts such as brackets, gaskets and busbars in electric racing cars to replace metal parts used in previous racing cars. Green Team also used ABS and PC to customize some covers and shells for different components.

3D printingIt has brought many benefits to the racing field, not only helping to shorten the development time of new designs, and producing end-use parts that can provide significant performance advantages. In the future, GreenTeam will continue to use INTAMSYS-Yuanzhu Intelligent 3D printingEquipment and high-performance materials to explore3D printingMore possibilities in formula racing.

How to apply high-performance materials in the wider manufacturing field3D printingtechnology?

The manufacturing technology of Formula Racing is at the forefront of development and manufacturing technology. In the process of joint development with the racing manufacturing team, machine tool and additive manufacturing equipment manufacturers have also refined advanced manufacturing processes to further confirm their market competitive position. There is no doubt that motorsport is still one of the technology accelerators. In the past ten years, additive manufacturing-3D printingTechnology has become an important part of the modern design and prototype of racing cars, as well as the manufacturing process of participating vehicle parts. Additive manufacturing parts have been continuously improved in motorsports, and will eventually extend from top to bottom to a wider business environment.So, how can the wider industrial manufacturing field make use of high-performance materials3D printingTechnology to achieve fast delivery, low cost and light weight?High-performance materials3D printingHow to help production?How do industrial manufacturing companies realize plastics3D printingSmall batch production of technology?

(Editor in charge: admin)

How high-performance material 3D printing is applied to the small batch production of terminal parts

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