Wheel bearing
Using beam melting all light weight potentials of the highly stressed parts could be achieved by a considerable topology optimization. Due to the large number of load alternations while racing a high component stiffness is needed. Even in complex geometrics, additive manufacturing can ensure high component stiffness of the parts.
Material: AlSi10Mg
Fuel anti sloshing system
The following example of an anti-sloshing-system fully proofs the opportunities of realizing complex geometrics with beam melting. The construction of a fluid dynamic optimized structure prevents the fuel pump from sucking air. Using directional dependent pressures the moving valves enable a lower fuel reserve in the tank. Furthermore it ensures a low center of gravity and reduces the weight of the car.
Material: AlSi10Mg
Cooling jacket
The cooling jacket is a component of an electric driven racing car. Using beam melting the part itself and the hose connections were manufactured in one component. An integrated, complex duct system is ensuring the best cooling of the electric engine.
Material: AlSi10Mg
Threading tool
The series tool was not ready yet, but the first customers should not wait. This is why the first serial parts for this threading tool have been produced within very short time via beam melting. Therefore the corresponding plastic parts have been casted in PU (rapid prototyping process).
Material: tool steel 1.2709 (plastic parts: P1015)
Jet engine housing part
Beam melting is perfectly suited for complex, thin walled parts. In this connection the aerospace industry can be provided with prototypes and series components. This example shows a prototype of a jet engine housing part with a diameter of 298 mm (11.7 in). Additionally to this part, typical design elements of aerospace parts got integrated: small hole diameters, thread elements, thin bracings and local material accumulations.
Material: stainless tool steel 1.2083
Sheet metal prototype
The tool less production via beam melting enables a rapid and cost-efficient supply of sheet metal prototypes for the automotive industry as well as other industrial sectors.
Material: AlSi10Mg
Lightweight bicycle crankset “Neo-Crankset”
Lightweight structures in terms of hollow and lattice-like structures and the production of topology optimized designs can be realized via beam melting technology. This example shows a lightweight crankset for bicycles. A key innovative feature is the sandwich design and a lattice-like structure in between the two walls, which makes an overall lightweight and stiff design possible.. Additionally, cavities and cross beams could have been realized in small angled sections. As a result the crankset weights less than 240 g. Due to this enormous reduction of weight compared to other lightweight cranksets with a minimum weight of approx. 300 g and due to the innovative design and manufacturing technology, this crankset was awarded with the Eurobike Award 2010 in the student category.
Design: Dipl.-Des. Robert Taranczewski
Material: AlSi12
Housing for an adaptronic control system
Beam melting is also applied for small series production of complex machine components. This example shows a housing part for an adaptronic control system. The difficulty of this component is the low wall thickness of only 0,3 mm in between the cavities for the adaptronic components. The realization of these cavities with the low wall thickness is very difficult although possible with means of conventional manufacturing technologies such as milling or spark erosion. In this project a small series production of four components has been realized. Benchmarks to other manufacturing technologies have shown that besides the enormous saving of time also an economic advantage have been achieved.
Material: tool steel 1.2709
Miniature heat exchanger
Complex coolers and heat exchangers can be realized by means of beam melting in one piece.
Material: stainless steel 1.4404
Turbine
Complex prototypes and small series for turbine wheels and blades can be produced within a very short time via beam melting technology. Additionally, almost arbitrarily complex cooling channels can be integrated into the component which otherwise are hardly or not producible with conventional production technology.
Material: Inconel 718 (nickel-base alloy)
