What if you could 3D print a car? What would you make? Would you quickly validate a new design concept with a functional prototype or would you explore low rate highly customized manufacturing for a specialized application? Perhaps you would use it as a tool to develop a new drive-train, energy storage subsystem or transportation concept with a functional vehicle level test.
The benefits of large format industrial metal multi axis hybrid additive manufacturing will be explained through the case study of 3D printing an aluminum chassis for a full-scale car. This new process provides true 3D free space additive manufacturing in an open shop environment and leverages well known CNC system controls. This process addresses well recognized limitations associated with metal additive manufacturing such as finished part size, dimensional tolerance and surface finish. A 250 cubic footwork volume allows a full auto chassis to be built as one complex structure. The benefits of integrated 5 axis CNC machining include dimensional control, surface finishing, improved metal quality deposition with a clean, flat, smooth substrate for every deposited layer and the industrially valuable ability to ‘go back and erase’ a few layers and then start again.
- Describe the benefits of large-scale industrial metal hybrid additive manufacturing
- Understand the benefits of true 3D free space additive manufacturing on the design of industrial metal structures
- Understand the benefits of a CNC controls driven industrial process that allows machining to occur during the 3D printing process for dimensional control, surface finishing, improved metal quality