Designing for AM Yields Lower-Cost, Lighter-Weight Auto Door-Hinge Part

January 19, 2022

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Designing for AM Yields Lower-Cost, Lighter-Weight Auto Door-Hinge Part
Specialists at Fraunhofer IAPT have employed additive manufacturing (AM) design methods to redesign a sports-car door-hinge arm, reportedly yielding a part at half the cost of the equivalent milled part, and boasting weight savings of 35 percent. Aided by software from 3D Spark (a Fraunhofer IAPT spinoff), Fraunhofer engineers first identified a suitable component for redesign from the ground up with AM in mind. Early in the project, they determined the cost-optimal AM orientation of the component and reportedly realized 15-perent cost savings. Then, optimizing geometry reportedly reduced part weight by 35 percent.

3D Printing Online Training Courses Available Now
If you’re looking to expand your knowledge in the additive manufacturing (AM) industry, EOS’ Additive Minds consulting team has the perfect solution for you. The Additive Minds Academy consists of individual online learning modules as well as more extensive learning paths to help you achieve your 3D printing goals.
View Courses Now

Desktop Metal
Pure Copper Qualified for Desktop Metal Binder Jetting
Desktop Metal announced qualification of pure copper (>95 percent) for AM on its Production System platform.  “Copper has been a highly requested material from many of our customers and prospects, and has applications spanning a broad variety of industries, from thermal hardware found in air and liquid cooling systems to conformally cooled coils for transmission of high-frequency currents,” explains Jonah Myerberg, Desktop Metal co-founder and chief technology officer.

2022 AMUG Conference – Join Us
The AMUG Conference brings a unique experience to additive manufacturing where attendees are eager to share insights. Designed to facilitate information exchange between AM users, the conference brings together individuals of all experience levels. Register now and save $400. Chicago, Illinois, April 3-7, 2022.

Nikon Metrology
Fundamental Research into the Microstructure of AM Components Using X-ray CT
A Nikon Metrology Model XT H 225 ST X-ray CT system installed at the University of Nebraska-Lincoln (UNL) Nano-Engineering Research Core Facility (NERCF) helps perform fundamental research into the effects of component geometry on overheating during metal powder-bed AM. Analyzing porosity on an Inconel 718 sample, the CT system’s resolution of 15 μm/voxel has been able to determine from the circularity of a pore whether it was formed by escape gas trapped in the melt pool or by incomplete fusion of the powder.

Says Prahalada Rao, associate professor from the UNL Mechanical and Materials Engineering department: “(The system) allows manufacturers greater control over the quality of AM or machined parts by allowing them to see flaws that previously were expensive and difficult to find.”

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Metal Binder Jetting Nets Positive Results for French Aerospace Supplier

Fall 2021
In This Issue
Industrialized 3D Printing Demands Connected Data
On the cusp of full-blown AM industrialization, to maintain the momentum gained during the pandemic, several crucial process and ecosystem evolutions must be more widely adopted to lower the barriers to AM.

Multiprocess AM: The Whole Is Greater Than the Sum of Its Parts
Combining multiple AM processes to create a single component offers a way to expand manufacturing capabilities to overcome key challenges.

Coming in 3DMP's Next Issue
  • AMUG (April 3-7, 2022, Chicago, IL) Preview
  • Directed Energy Deposition
  • Software for Metal AM
  • Metal-AM Powders
  • Formnext Wrapup

Industry-Related Terms: Core, Hardware, Model
View Glossary of Metalforming Terms



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