Printed Car Parts: 3 Examples of Innovative 3D Printing at Porsche
More horsepower for the 911 GT2 RS, original spare parts for the Porsche Classic range and personalized sport seats
Porsche is using 3D printing technology to revolutionize product development and production. 3D-printed pistons, spare parts and sport seats are three use cases where this technology is taking automotive engineering to the next level.
Additive manufacturing, also known as 3D printing, has existed since the 1980s, but only in recent years has it begun to make a significant impact on manufacturing. While it is still primarily used for prototyping purposes, it promises to become a game-changer across industrial sectors (including aerospace, health care and food). In fact, it is a new medium for innovation and has the potential to fundamentally transform how manufacturing is done.
The additive manufacturing process removes many of the constraints associated with traditional manufacturing and allows for greater customization and more complex designs, while also reducing production steps and material input. Three-dimensional objects are produced by adding sequential layers of material, rather than removing material through milling, cutting, or drilling.
Capturing the full potential of additive manufacturing
3D printing is also starting to make major inroads into the automotive industry, with more and more suppliers and carmakers adopting the technology. At Porsche, we are currently identifying where additive manufacturing might offer significant improvements over traditional production methods and how it can be applied for serial products. We collaborate with partners and other service providers to capture the technology’s full potential and to develop innovative manufacturing processes. Recently, we have begun to use 3D printers to manufacture functional parts such as pistons, replacements for the Porsche Classic range or sport seats.
Cutting-edge manufacturing: 3D-printed pistons for the 911 GT2 RS
By using 3D printing technology, we are now able to produce innovative high-performance pistons for the twin-turbo boxer engine of our 911 flagship model, the GT2 RS.
The printed pistons are ten percent lighter than the standard forged pistons and have a better thermal resistance, featuring an integrated and closed cooling duct in the piston crown that reduces the temperature in this area by more than twenty degrees Celsius. The project has been realized in collaboration with MAHLE, a pioneering automotive supplier, and TRUMPF, a leading laser and mechanical engineering company.
The lightweight, high-strength pistons increase both efficiency and performance of the GT2 RS, leading to a 30-horsepower gain. They are printed from high-purity metal powder, made of a special aluminum alloy developed by MAHLE, using a laser metal fusion process — an additive manufacturing process in which a laser melts the powder into 1.200 layers to form the desired shape. To manufacture the pistons, TRUMPF used its TruPrint 3000, a precision machine with a 500-watt fibre laser that puts the material exactly where it is needed.
Experts from Zeiss, a German manufacturer of optical systems and optoelectronics, validated the 3D-printed pistons’ design and reliability using light microscopy, scanning electron microscopy and X-ray computer tomography. In addition to Zeiss’ measurement technology, we also put the pistons through a 200-hour endurance test on a test rig. All pistons passed the test.
Innovation meets tradition: original spare parts from a 3D printer
Since 2018, Porsche also uses additive manufacturing to manufacture parts that were formerly out of production. Thanks to 3D printing, out-of-stock spare parts can be reproduced on demand. Currently, we manufacture around twenty parts (including plastic, steel and alloy parts) for the Porsche classic range and are testing production of further components.
For example, to manufacture the release lever for the clutch on the Porsche 959, we use selective laser melting. A high-energy light beam melts the powder in the desired locations, solidifying successive layers of material to create the three-dimensional object.
New bucket seats for the 911 and 718
Another use case where we harness the power of additive manufacturing are personalized sports seats. Since May, forty 3D-printed bodyform full bucket seats are available for use on racetracks from Porsche Tequipment for the Porsche 911 and 718. Here, the central section of the seat is partly produced by a 3D printer. We are currently collecting feedback from customers, which is incorporated into the ongoing development process of the street-legal full-bucket seats that will be available from the Porsche Exclusive Manufaktur from mid-2021.
Designing the sports cars of tomorrow
Traditional production processes will continue to have their place in automotive manufacturing, of course. Yet, additive manufacturing offers significant potential in the area of product and process innovation, allowing for new levels of complexity and performance. At Porsche, we will continue to adopt this technology to take advantage of the complexity that is possible with 3D printing, improve our products, and build the most compelling sports cars for our customers.
About this publication: Where innovation meets tradition. There’s more to Porsche than sports cars — we’re tackling new challenges, develop digital products, and think digital with a focus on the customer. On our Medium blog, we tell these stories. It’s about our #nextvisions, smart technologies, and the people that drive our digital journey. Please follow us on Twitter (Porsche Digital, Next Visions), Instagram (Porsche Digital, Next Visions, Porsche Newsroom), and LinkedIn (Porsche AG, Porsche Digital) for more.
