Additive Manufacturing Special Report - November 2023 - 2

3D,
NO WAITING!
Two companies'
latest techniques take additive
manufacturing to the next level.
by John Dinkel
The " business " ends of Czinger's 21C are 3D-printed structures that connect to the central carbon-fiber tub.
Weight savings of 30 percent to 40 percent are achieved via the patented Czinger technology.
F
ew will dispute that additive manufacturing - commonly
called 3D printing - has endured a development path of fits
and starts. But as niche applications, an ever-increasing
array of material choices - and the innovative specialists
nurturing it all - continue to thrive, additive manufacturing
continues on a steady track toward its longstanding twin challenges
of cost- and throughput-competitiveness with traditional
manufacturing processes.
Recently, Automotive Engineering spoke with two key advocates of
3D printing, Los Angeles' Divergent/Czinger 21C and 3D Systems,
based in Rock Hill, South Carolina. Each is executing a unique
strategy to explore and advance the future of additive
manufacturing.
Divergent CEO Kevin Czinger, along with his COO son, Lukas, are
engaged in a long-view effort to reinvent automotive manufacturing
from the bottom-up, starting with a chassis built entirely using
3D-printing technology.
The Divergent Adaptive Production System (DAPS) is a complete
software-hardware solution designed to replace traditional vehicle
manufacturing. It essentially is a complete modular digital factory for
complex structures. Given a set of digital requirements, DAPS
automatically computationally engineers, additively
manufactures and assembles any complex structure. The system is
able to switch seamlessly between manufacturing different vehicle
models.
DAPS uses generative AI and 3D modeling in the design process.
Using additive manufacturing, Divergent can print complex
geometries and lighter-weight parts and assemblies. DAPS abolishes
casting molds and stamping dies and uses bonding instead of
welding. It also eliminates the need for fixtures in the assembly
process.
2 NOVEMBER 2023
3D Systems, meanwhile, takes a different approach
- the company is a one-stop shop for " everything
additive. " It not only is a supplier of material, software,
hardware and services, but also is a key user. 3D
Systems says, " We push the boundaries with expert
additive-manufacturing solutions and consultation
that make the existing better and the new possible. "
In the automotive sector, 3D Systems touts 58
percent lower development costs for critical systems
and 10 times acceleration of product-development
projects. According to Pat Warner, advanced digital
manufacturing manager of the Alpine Formula One
team, " It's been exciting to co-develop [with 3D
Systems] Accura Composite PIV and see the benefits
it's bringing to our process. "
Particle Image Velocimetry (PIV) is a non-intrusive
optical-flow measurement technique used to study
fluid flow patterns and velocities. 3D Systems'
Accura Composite PIV is a new material specifically
designed to address PIV testing applications used
primarily in motorsports wind-tunnel testing.
Accura Composite PIV can produce rigid parts in
a high-contrast color optimized for PIV testing.
Czinger's High-Performance Vision
for Additive Manufacturing
SAE: You've called the Blade a demonstration vehicle
for a new technology and a new system. How far
have you advanced the technology from the 2016
Blade to the 2023 Czinger 21C Hyper car?
ADDITIVE MANUFACTURING SPECIAL REPORT
CZINGER VEHICLES

Additive Manufacturing Special Report - November 2023

Table of Contents for the Digital Edition of Additive Manufacturing Special Report - November 2023