Automotive Engineering - August 2021 - 22

3D printing SCALES-UP
AM is and will be a key technology in manufacturing, not only for
prototype parts but also for serial production.
outfitted with equipment from 3D Systems, EOS, Stratasys
and Carbon 3D. Additive processes performed at the center
include fused deposition modeling (FDM); selective laser
sintering (SLS); stereolithography (SLA); multi-jet modeling
(MJM) and digital light processing (DLP).
Prototype builds are a primary focus at TMNA. Some prototypes
are used for appearance confirmation, some for functional
checks and still others for workability studies. The models
are used to support both traditional vehicle development
projects as well as new mobility and advanced development
initiatives that Toyota is undertaking.
Tooling-build use of AM includes process jigs that are used
to ensure that the vehicles' exterior emblems are correctly
assembled during pre-production trials at the facility. The jigs
then are used in Toyota's North America production operations.
Challenges in adopting AM for volume production being
addressed at TMNA include matching the properties of the
materials currently being used in production operations; being
able to scale-up additive output to support high-volume
production needs and increasing processing speeds.
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Highly complex parts produced quickly using Mahle's laser powder bed
3D printing process.
Mahle tests materials for AM
Slashing prototype lead times from several months to a few
days explains in part why Mahle's technology group decided
to build a new facility for additive manufacturing (AM) processes
at its Stuttgart headquarters. The 3D printing center
houses the printers, powder-preparation module, testing laboratory
and a blasting system for finish machining the components
to satisfy internal prototype production as well as automotive
and commercial-vehicle customer orders.
" The development of new systems and components has to
be much faster today than it was a few years ago, especially
when it comes to e-mobility, " Andreas Geyer, head of Process
Technologies in Central Research at Mahle, said during a recent
press event introducing Mahle's new AM capabilities.
" We are boosting the performance of our existing portfolio
through possibilities in production design. "
Another reason for opening such a facility is to enable 3D
printing for series production that meets the strict standards of
the mobility industry. The focus is on developing and qualifying
manufacturing processes for components in thermal management,
mechatronics and electronics - for example, to produce
transmission and electric motor housings, charge air coolers, oil
filter housings and heat exchangers, as well as structural elements,
mounting devices and connections.
" We want to be prepared today to find out how we can use
an integrated 3D printing [development process] according to
automotive standards for later large-scale production, " Geyer
said. " This opens up completely new possibilities in product
development and manufacturing, because these processes
can be used to produce high-performance components that
cannot be manufactured using conventional methods. "
The center processes two standard metal materials: aluminum-silicon-magnesium
(AlSi10Mg) and stainless-steel 1.4404
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Automotive Engineering - August 2021

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