Joyson Security Methods (JSS), a Michigan-headquartered mobility security specialist, has used SLS 3D printing with CRP Expertise’s carbon bolstered composite materials Windform SP to fabricate a purposeful airbag housing container prototype.
Seeking to discover the potential of additive manufacturing in its manufacturing processes, the JSS Core improvements crew sought to fabricate a purposeful Driver Airbag (DAB) housing half prototype in a matter of days, as an alternative of months. It was vital for JSS that the prototype was made out of composite supplies which had been nearly comparable in mechanical, thermal properties and efficiency to the unique DAB housing supplies, and thus opted to make use of the Windform SP carbon bolstered composite materials.
“After working some market evaluation with the intention to discover out essentially the most appropriate materials and course of that might ship the required efficiency, we got here throughout the Windform TOP-LINE household of composite materials and, particularly, the Windform SP,” feedback Samer Ziadeh and Daniel Alt from JSS’ Core improvements crew.
“Windform SP introduced our consideration to the truth that it’s a cloth produced from polyamide PA grades and bolstered with Carbon fiber as a powder kind materials, and it has nearly the required and even higher efficiency for our software.”
3D printed Driver Airbag (DAB) housing in Windform SP inside view. Picture by way of CRP.
Producing a purposeful prototype in days with CRP’s 3D printing service
A world chief in mobility security, JSS is a supplier of safety-critical parts, techniques and expertise to automotive and non-automotive markets. A subsidiary of Ningbo Joyson Digital Corp, a Chinese language automotive conglomerate, JSS manufactures security merchandise corresponding to airbags, seatbelts, steering wheels and security electronics and supplies them to prospects worldwide.
The JSS Core improvements crew lately launched into a undertaking to discover the potential of 3D printing expertise in establishing new manufacturing processes and using new supplies, notably in relation to producing DAB containers.
The crew carried out market evaluation to determine a composite materials equivalent to the prevailing materials used within the manufacturing of the airbag housing container, which on this case was PA6-GF40, a polyamide with 40 p.c glass fiber reinforcement. The housing is often produced by way of injection molding. Your entire DAB system consists of an inflator, an airbag cushion, a canopy and a housing with attachment factors on the steering wheel.
An integral security element of any automobile, making certain the efficiency of the DAB housing half is important. Ziadeh and Alt clarify the perform of the DAB housing, commenting that “It’s to resist a excessive quantity of dynamic masses along with holding the inflator and the airbag cushion fastened in location throughout and after the deployment of the airbag system […] The take a look at procedures are usually carried out inside a numerous vary of temperatures between -35°C and +85°C.”
Thus, the fabric for manufacturing the half is anticipated to take care of ample power, impression resistance and warmth stability to carry out correctly underneath totally different testing circumstances, with comparable properties to the unique materials. Searching for to provide the half in a matter of days with 3D printing, the crew needed to enhance upon the time-consuming and extremely tooling prices of the standard course of.
Airbag deployment take a look at. Picture by way of Joyson Security Methods
The JSS Core improvements crew turned to CRP Expertise, an Italian 3D printing supplies producer, specifically in search of to leverage the corporate’s TOP-LINE vary of excessive efficiency supplies, in addition to its in-house 3D printing service. Windform SP was recognized as essentially the most appropriate materials, a carbon fiber bolstered composite polyamide powder for SLS 3D printing. The fabric is appropriate for functions resistance to impression, vibration, deformation, and excessive temperatures, notably in automotive.
Utilizing the Windform SP carbon composite materials, JSS was in a position to produce a purposeful DAB housing prototype and to check it in a whole airbag module inside a brief time frame. The fabric reportedly exhibited wonderful mechanical efficiency when it comes to excessive power and impression resistance in addition to good thermal stability between a high and low vary of temperatures (RT; 23°C, -35°C & 85°C).
Ziadeh and Alt add, “Additionally the prototype half demonstrated excellent efficiency throughout numerous testing circumstances, which has confirmed the actual fact of half performance for an entire consideration of a brand new product improvement. Principally the professionals through the use of the SLS course of is the chance to make use of bolstered polymers with excessive mechanical efficiency and stability.”
3D printed Driver Airbag (DAB) housing in Windform® SP manufactured by way of Laser Sintering course of. Picture by way of CRP Expertise
The CRP Windform Prime-Line vary of 3D printing supplies
CRP Expertise’s Prime-Line vary of Windform supplies has been leveraged for quite a few end-use and prototyping functions within the aerospace and automotive trade.
The Windform SP product itself has beforehand been used to 3D print a purposeful Nationwide Advisory Committee for Aeronautics (NACA) duct for the Streamliner race automotive automobile. The Victory Motorsport’s Workforce Streamliner automotive went on to interrupt a long-standing pace file at Bonneville Pace Week in 2018 – a motorsport occasion testing custom-made land autos.
Additionally included within the Prime-Line vary are Windform LX 2.zero, Windform XT 2.zero, Windform GT, which alongside WIndform SP have handed NASA’s outgassing exams.
Lately, CRP Expertise expanded the Prime-Line vary with the addition of two flame-retardant supplies – the Windform FR1 and Windform FR2. The latter has already been utilized by Energica Motor Firm, an Italian producer of electrical bikes, to manufacture cell pouch frames for its battery pack prototypes.
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Featured picture exhibits 3D printed Driver Airbag (DAB) housing in Windform® SP manufactured by way of Laser Sintering course of. Picture by way of CRP Expertise
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