3D prints casting cores for all-electric sedans
A US company is using a German supplier's 3D printers to mass-produce structural components for all-electric sedans. According to the manufacturer, it prints cast cores of large-format, weight-saving structural components using the world's largest 3D sand printers, which simplifies production compared to conventional manufacturing.
Each casting replaces up to 40 componentsIn the production of each vehicle underbody, the manufacturer needs a total of 51 additively manufactured sand cores. With the supplied 3D printing system, he prints hundreds of inner cores in one night. After printing, the cores are smoothed, coated with a fireproof coating, placed in sand molds and finally cast in a low-pressure filling process.
Each of the six sand-cast parts reduces the total number of components by 30 to 40 compared to a typical stamped structure, he said. Because each structural part has fully machined interfaces, the six castings can be assembled precisely, and tight tolerances can be maintained for assembly fabrication.
Lean production with easy assemblyThe large-format mold and core printing of the 3D printers makes production leaner, thus faster and more economical, compared to conventional manufacturing. Significantly fewer components are needed, which simplifies and speeds up assembly.
By eliminating tools and taking advantage of the large build volume of the VX4000 printers, we can significantly reduce delivery times and produce lightweight components with optimized topologies. This would not be possible in the conventional way.