Home Applications & Case Studies EPlus3D: 3D printed metal parts for racing cars

EPlus3D: 3D printed metal parts for racing cars

Chinese 3D printing specialist Eplus3D has printed titanium and aluminum parts for the Delta Racing team’s race car. In the process, the team achieved a weight saving of 60%.

To achieve this, the Delta Racing Team used the SKO (Soft Kill Option) method to identify all the areas where material is not needed. In areas of high stress, the E-module is increased in the simulation, while in areas of low stress, it is decreased. In conclusion, the software creates a function of the E-Modul about the tension in the different regions of the part.

For the Simulation the following aspects need to be defined:

  • All different angles and load cases
  • The boundary  and ancillary condition
  • The loads of the system

Afterwards, the program calculates the optimum shape of the diverter for all the load cases. As a result, the safety factor and the force flow can be controlled.

Design for Manufacturing

For better results, the generated topology optimized geometry needs to be improved. For this step, different approaches can be used. The Delta Racing team works with Solidworks to reconstruct the shapes with curves, avoiding sharp and small corners. To validate the generate design, a mechanical structure analysis must be performed.

The automotive parts and accessories market is an important source of revenue for global automotive manufacturers. With the 3D technology it is possible to print parts with geometries, that are difficult to realize with conventional methods, and it is also more cost effective, when non series production take place.

An example of this can be seen on pictures below. The wishbone is used to connect carbon tubes, which are used in the suspension with each other and with other components such as the above described diverter. Eplus3D supported the team in manufacturing the parts using Ti6Al4V Titanium Alloy powder. In this case, Delta Racing could fulfil their design requirements, resulting in a win-win situation regarding cost and weight. In an average, the weight could be reduced by over 50% and the whole car could benefit of a weight reduction of around 3kg.

The MPBF printing technology, not only allows the user to produce high performance parts, it also improves the efficiency of whole chain, from production time to the performance of the part.

In this case the delta racing team decide to print the diverter with a titanium alloy, saving more than 60% of weight. The weight was reduced from 240g to 91g per part, what means around 600g less for the racing car. In addition additive manufacturing offers the team maximum geometric design freedom and due to the lower material consumption, costs can often even be reduced significantly.

Find out more about Eplus3D at eplus3d.com.

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