Kempten University of Applied Sciences is working on the development of sustainable lightweight structures for city buses and coaches as part of the CO2OPERATE project funded by the German Federal Ministry for Economic Affairs and Climate Protection. The aim is to use additive manufacturing to reduce the use of energy and resources both in the production and operation of vehicles. The focus is on components that can be manufactured or repaired using processes such as laser powder bed fusion (LPBF) or laser metal deposition (LMD).
“The plan is to develop ten component designs, five of which will be examined in detail for their ecological and economic impact,” explains Professor Frieder Heieck, Scientific Director at the IPI.
A key element of the project is the integration of so-called R-strategies, for example for the reuse and repair of components. At the Institute of Production and Information Technology (IPI) at Kempten University of Applied Sciences, existing components are analyzed and evaluated to determine whether they are suitable for additive redesign. Methods such as generative design and functional integration are used to save material and increase durability at the same time. The effects of these new designs on the environment and economic efficiency are recorded using a life cycle analysis (LCA). This analysis takes into account both the manufacturing phase and the use and possible reuse of the components.
“These processes make it possible to further process prefabricated components or to specifically renew worn components instead of manufacturing them from scratch,” emphasizes sub-project manager Matthias Duve.
The aim is to reduce energy consumption during production by up to 13,500 kWh per bus and at the same time reduce vehicle weight, which has a positive effect on energy consumption during operation. Post-production processes are also being optimized in the project in order to increase efficiency along the entire process chain. Project partners include Daimler Buses and ARRK Engineering, while associated industrial companies such as TRUMPF are supporting the project.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
