How additive manufacturing with special thermoplastic composites is driving the automotive and transport revolution
How additive manufacturing with special thermoplastic composites is driving the automotive and transport revolution
The transportation industry is undergoing profound changes including a shift towards demanding electric vehicle (EV) requirements, and more OEM manufacturers are being faced with the challenge of transitioning towards electric and new technology production lines.
In this transformative landscape, additive manufacturing (AM) has emerged as a key enabler, capable of addressing new demanding criteria. However, the success of this approach hinges on the meticulous selection of high-performance materials capable of meeting the functional and structural demands of critical components. Additionally, materials may need to be ESD compliant (minimising electrostatic discharge) to ensure safety and reliability in sensitive electronic environments. In other cases, they might need to exhibit marked dielectric properties to efficiently insulate and manage high-voltage components in EVs. Windform’s 3D composite range encompasses materials accomplishing such demanding criteria.
THE ADVANTAGES OF AM
AM eliminates the need for traditional tooling, significantly cutting down initial setup times and costs. The process is inherently efficient, minimising material waste while maintaining the high precision required for complex components. This immediate production capability empowers companies to respond quickly to market demands and technological advancements.
While upgradings in battery capacity have been crucial in extending the range of EVs, optimising new vehicle efficiency remains a key focus in their development. As such, industrial 3D printing service provider CRP Technology has pinpointed three core aspects that significantly enhance vehicle optimisation: powertrain efficiency, retaining part resistance to harsh conditions, reduction of vehicle mass and aerodynamic drag.
HIGH-EFFICIENCY POWERTRAINS AND COMPONENTS
The safety and adaptability of Windform Composites to demanding transport requirements stems from three decades of expertise in the challenging world of motorsport and hypercars, which serves as a rigorous testing ground where additively manufactured components are required to excel in both reliability and efficiency under extreme operating conditions.
The readiness of the Windform material range lies in its unique combination of properties, ranging from high strength and lightweight characteristics to resistance to extreme operating temperatures, corrosion, water and fluid ingress, even over extended periods of time and upon high speed and vibrations. These attributes enable the creation of highly efficient components for critical areas such as cooling systems and air intakes where thermal stability and resistance to fluid exposure are crucial, and the cooling section of braking systems and pipes which require precise tolerances and durability under repeated stress.
OPTIMISED RETAINING SYSTEMS
Additively manufactured retention systems are preferred for their ability to securely organise high-power cables and electronics in modern vehicles, which are defined by their connectivity and the demand for specialised harnessing systems. These components are designed to safeguard electronics, fluids, cooling ducts and super high-power energy cables, and are capable of carrying a variety of signals or fluids and optimise spaces.
Made in all-in-one dielectric enclosures, 3D printed retention systems ensure both efficiency and safety, even for EV high-power cables, thanks to the use of dielectric materials with superior dielectric strength exceeding 2.5kV/mm. These components are designed for easy access, simplifying inspection and maintenance, while ensuring high performance and reliability in demanding automotive environments.
REDUCING MASS AND WEIGHT
CRP Technology has consistently leveraged the lightweight properties of its Windform composite materials which feature an extremely low density and high strength-to-weight ratio. The reduction in mass, which averages around 30%, translates to improved efficiency and agility, particularly in high-performance vehicles.
Cost efficiency is a significant factor in high-performance applications, where precision and customisation are key. CRP Technology’s use of SLS 3D printing with Windform composites eliminates the need for traditional tooling, reducing upfront costs. Additionally, the process minimises material waste while maintaining high precision, making it an environmentally friendly manufacturing method.
Windform Composites have been successfully used within ducts, oil pan baffles, intake manifolds, braking systems and powertrain components where the reduced weight not only supports faster acceleration and improved handling but also contributes to overall energy efficiency, a critical factor in modern vehicles. By enabling lighter yet robust designs, CRP’s Windform solutions push the boundaries of engineering possibilities.
In the fast-paced world of high-performance applications, the ability to drastically reduce time to market is crucial. CRP Technology leverages the power of AM, specifically through SLS 3D printing with Windform composites, to enable rapid production of functional prototypes and low-volume production runs. This not only speeds up the development process but also allows companies to swiftly bring innovative products to market.
Laura Fabbi is at CRP Technology.
