#LIGHTWEIGHTING

Automotive

Metal Additive Manufacturing on the Track

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

Automotive

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

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.

Tooling

How 3D Printing Will Change Composites Manufacturing

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.

Materials

Stratasys’ Carbon Fiber Material is Stronger, Stiffer ABS

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

Automotive

Porsche Advances Electrification with Generative Design

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

Aerospace

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

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.

Design

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

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. 

Automotive

Generative Design Improves Micromobility FUV: The Cool Parts Show S3E3

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.

Design

Generative Design to Bring Weight and Cost Savings for Micromobility FUV

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.

Materials

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

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.

Tooling

Lightweight Sandvik Cutting Tool Employing Topology Optimization Now Available

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

Automotive

GM Seat Bracket Made with Autodesk Generative Design Software

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.

Design

Altair Releases Inspire2018 Simulation-Driven Design Software

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

Lightweighting with Lattices

Building components as a network of unit cells may improve material utilization and performance. 

Xact Metal Launches Industrial-Grade XM300 Metal 3D Printer

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

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.

Production

Windform Composite 3D Printing Materials Enable Lightweight, Flexible Air Inlet

CRP Technology recently developed a new front air inlet for a Moto3 racing customer, which was manufactured in Windform materials by using an SLS additive manufacturing technique.

Design

Airbus Partition Built in Pieces for Weight Savings

The large component was successfully produced within a limited build envelope thanks to connection features designed into the pieces. Advances in powder-bed build size will permit greater efficiency in producing parts such as these.

Design

Design for AM: Diesel Engine Support Optimized for Savings and Performance

A diesel engine support, connecting the powertrain and the vehicle chassis, is optimized for weight savings, performance and manufacturing cost reduction as a result of redesigning the part for AM.

Consumer Goods

Lightweight Motorcycle Made Through AM to Be Seen at IMTS

Additive manufacturing allowed electric bike’s frame to be optimized for minimal mass and material.

Design

SLM Achieves Weight Reduction for Robot Actuator

Selective laser melting made it possible to create a lighter, better performing actuator for a quadruped robot.

Automotive

Modular, Lightweight Car Design Made Possible through Metal AM

The concept car’s frame is built on load-optimized nodes that could only be made with additive manufacturing.

Aerospace

Additive Manufacturing and Cost per Kilogram

How much is weight savings worth to you? Additive is being embraced in applications where the answer to that question is high.

How Do You Make a Howitzer Less Heavy?

Large nuts that used to be solid metal are now grown with a honeycomb structure on the inside for valuable weight savings.

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