#LIGHTWEIGHTING

Production

Solving MRO Challenges with Bound Metal Deposition

By: Evan Doran

Three case studies reveal how Desktop Metal’s second-generation Studio System bound metal deposition printer eliminates common safety hazards of metal AM, enhancing the technique’s value for maintenance, repair and operations (MRO) applications.
#lightweighting #metal #topologyoptimization

Tooling

Sand 3D Printing Benefits Lightweighting and EV Production

Edited by Evan Doran

Brooks Crownhill Limited has used Voxeljet’s sand 3D printers to rapidly prototype automobile part molds, with the increased design flexibility enabling lightweighting while strengthening individual components.
#sand #lightweighting #casting

Materials

Lightweight Combustion Chamber for 3D Printed Rocket Engine: The Cool Parts Show #30

By: Peter Zelinski, Editor-in-Chief

An engine for repeated trips to the moon is 3D printed in just three pieces from a metal matrix composite combining aluminum for weight saving with ceramic for high-temperature performance.
#assemblyconsolidation #lightweighting #ceramic

Aerospace

Safran, SLM Solutions Test Technology for Large Airplane Component

Edited by AM Staff

In a joint project, Safran Landing Systems and SLM Solutions tested selective laser melting to produce a component of a nose landing gear for a bizjet, marking a world first for a part of this size.
#lightweighting #metal #largeformat

Automotive

Metal Additive Manufacturing on the Track

Edited by Julia Hider, Associate Editor

Additive manufacturing and topology optimization are helping teams produce stronger, lighter parts that meet the demands of off-road racing vehicles.
#lightweighting #metal #topologyoptimization

Design

Lighter, Better-Performing Brake Rotor From 3D Printing: The Cool Parts Show #27

By: Peter Zelinski, Editor-in-Chief

Additive manufacturing with an aluminum/ceramic composite enables a brake rotor with one-third the weight and five times the heat transfer of a typical rotor. We talk to the inventor on this episode of The Cool Parts Show.
#lightweighting #ceramic #video

Tooling

How 3D Printing Will Change Composites Manufacturing

By: Peter Zelinski, Editor-in-Chief

A Q&A with the editor-in-chief of CompositesWorld explores tooling, continuous fiber, hybrid processes, and the opportunities for smaller and more intricate composite parts.
#lightweighting #composites #brackets

Materials

Stratasys’ Carbon Fiber Material is Stronger, Stiffer ABS

Edited by AM Staff

Strong, lightweight, ABS-based material is specifically formulated for applications such as manufacturing tooling, jigs and fixtures.
#lightweighting #composites #polymer

Automotive

Porsche Advances Electrification with Generative Design

By: Gary S. Vasilash, Transportation Editor

The sports car manufacturer achieves weight savings and assembly consolidation using additive manufacturing instead of casting for an electric drive housing.
#assemblyconsolidation #lightweighting #generativedesign

Aerospace

3D Printed Parts on the Mars Perseverance Rover: The Cool Parts Show #23

By: Peter Zelinski, Editor-in-Chief

The Perseverance parts made through additive manufacturing are extreme examples of lightweighting. We have replicas of the 3D printed parts that were sent to Mars.
#lightweighting #metal #video

Design

How 3D Printing Enables More Sustainable Designs (Video #2)

By: Stephanie Hendrixson, Senior Editor

The circular economy needs the lightweight, optimized and efficient designs that only 3D printing can provide. More in this video, part of our series on 3D Printing and the Circular Economy. 
#lightweighting #sustainability #video

Design

Generative Design Improves Micromobility FUV: The Cool Parts Show S3E3

By: Peter Zelinski, Editor-in-Chief

Arcimoto’s lightweight “Fun Utility Vehicle” gets even lighter thanks to parts that could only come from additive manufacturing. On this episode of The Cool Parts Show, some of the craziest automotive parts you have seen.
#assemblyconsolidation #metal #coolparts

Automotive

Generative Design to Bring Weight and Cost Savings for Micromobility FUV

By: Peter Zelinski, Editor-in-Chief

The “Fun Utility Vehicle” from Arcimoto is already in production, and already lightweight. But after just 30 days of redesign for additive manufacturing, the company discovered major components could be made lighter still, and production could be made simpler.
#assemblyconsolidation #metal #generativedesign

Materials

Are Crystals the Key to 3D Printing with Silicon Carbide?

By: Peter Zelinski, Editor-in-Chief

If SiC was easier and cheaper to apply, we would find many more uses for this hard, lightweight ceramic. Researchers have found a promising additive manufacturing approach, with crystal growth as the bonding mechanism.
#composites #ceramic #lightweighting

Tooling

Lightweight Sandvik Cutting Tool Employing Topology Optimization Now Available

By: Peter Zelinski, Editor-in-Chief

Additive manufacturing aids “subtractive” CNC machining. We first saw this tool in an early version last year. See the video in this post.
#metal #machining #topologyoptimization

Automotive

GM Seat Bracket Made with Autodesk Generative Design Software

By: AM Staff

The bracket is the result of a multi-year alliance between the two companies to explore generative design, AM and materials science for vehicle lightweighting.
#brackets #generativedesign #lightweighting

Design

Altair Releases Inspire2018 Simulation-Driven Design Software

By: AM Staff

The software enables rapid simulation, gives insight into lightweighting, and can be used by businesses with little or no simulation experience.
#lightweighting

Lightweighting with Lattices

By: Timothy W. Simpson, Paul Morrow Professor of Engineering Design & Manufacturing

Building components as a network of unit cells may improve material utilization and performance. 
#metal #lightweighting #supplychain

Xact Metal Launches Industrial-Grade XM300 Metal 3D Printer

By: AM Staff

A lightweight, high-speed gantry is key to the powder-bed fusion system’s speed.
#metal #lightweighting

Meeting the Machining Challenges of Additive Manufacturing

You can 3D print the part, but can you finish it? Here is how to overcome the challenge of part deflection in the machining of lightweight, complex AM parts.
#metal #lightweighting #machining