Stavari project looks to additive manufacturing for car manufacturing
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StaVari venture seems to be to additive manufacturing for automobile manufacturing

StaVari is a analysis venture, led by German-based automotive engineering service supplier EDAG Group, aiming to create a totally built-in additive manufacturing course of chain for the manufacturing of automotive parts. The venture, consisting of 9 different analysis companions, goals to supply the elements utilizing a newly developed metal powder alloy, tailored for automobile physique purposes, and laser additive manufacturing (LAM).

The results of the analysis is a manufacturing cell geared up with robots for an automatic additive manufacturing course of able to producing complicated automotive parts. Companions of the StaVari venture embrace GE-owned steel 3D printer producer Idea Laser, in addition to Ziehm Imaging, Salzgitter Mannesmann Forschung, Cloos, hema digital, Indutherm, IWT Bremen, Fraunhofer IAPT and SLK TU Chemnitz. The venture can even obtain funding from the Federal Ministry of Schooling and Analysis (BMBF) till April 2020. 

The StaVari totally built-in course of chain for the additive manufacture of complicated parts . Picture by way of EDAG.

3D printing on the EDAG Group

Based in 1969, EDAG works within the area of product and manufacturing plant improvement. It’s thought of one of many world’s largest impartial improvement companions of the automotive trade, and has developed quite a lot of idea automobiles for varied automotive companies, a few of which it has made with the assistance of 3D printing.

In April 2019, EDAG and Siemens introduced a strengthening of their partnership the place each agreed to speed up additive manufacturing within the automotive trade. Collectively, the companions developed the Subsequent Era Area body 2.zero, a modular aluminum construction with bionically designed and additive manufactured nodes. Although sharing comparable objectives as its collaboration with Siemens, EDAG’s StaVari venture is a separate initiative fashioned to open up automotive alternatives particularly for steel 3D printing.

StaVari venture seems to be to additive manufacturing for automobile manufacturingMartin Hillebrecht, Head of Improvements EDAG Engineering GmbH, Rainer Wittich, CEO EDAG Manufacturing Options GmbH & Co. KG meet Dr. Wolfgang Heuring, CEO Enterprise Unit Movement Management at Siemens and Dr. Karsten Heuser, VP Additive Manufacturing at Siemens (from left) on the Siemens EDAG “NextGenSpaceframe 2.zero” Automotive use case. Picture by way of EGAD.

Supporting car variants utilizing steel additive manufacturing

Step one taken by the StaVari companions was growing a metal alloy powder designed particularly for automobile physique purposes. After 3D printing, this powder alloy is alleged to have properties akin to these of DP800 dual-phase metal. The fabric can doubtlessly scale back prices (approx. 60 p.c) in comparison with standard alloys too. 

Following materials improvement, the subsequent step of the venture was to develop ideas for part designs primarily based on necessities specified by EDAG. At this stage, the companions additionally developed materials parameters, materials maps and CAE design strategies. 

Following the design section, EDAG regarded to the availability chain: powder manufacturing and atomization, LAM, thermal therapy and put up processing. Initially developed for lab use, new strategies for becoming a member of LAM parts have been explored, then scaled up to be used in an industrial setting. Meeting of LAM elements is now undertaken by a robotic manufacturing cell in a camera-controlled steel lively gasoline (MAG) welding course of. Considerably, this manufacturing cell minimizes the necessity for tooling parts that will be utilized in conventional manufacturing strategies. 

With the manufacturing course of refined, EDAG engineers then set in the direction of designing a heavy-duty car construction, which was manufactured in cooperation with all companions as a demonstrator of the venture. The stricture contains the pillars of a automobile (i.e. vertical window helps). LAM was used to supply the foot reinforcement of the central pillar welded with a historically manufactured load path-compatible rear pillar node. Based on EDAG, the bionic construction and cargo level-specific capabilities of the construction demonstrates new approaches for the automotive trade. The corporate additionally hopes that the findings of StaVari may help shorten the time-to-market for prototypes and small collection automobiles with steel-based our bodies sooner or later.

Concept of highly loaded multi-functional and variant-intensive vehicle structure. Image via StaVari.Idea of extremely loaded multi-functional and variant-intensive car construction. Picture by way of StaVari.

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Featured picture exhibits the StaVari totally built-in course of chain for the additive manufacture of complicated parts . Picture by way of EDAG.

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