3D printed cars in the future ?

[composimmonite]

Although looking a bit crude at present 3D printed cars are already been developed -

So when the technology is perfected what bodyshell would you like being reproduced that could then be fitted to a proper chassis with modern / common running gear making even "exotica" possible ? Obviously there is the MKI Escort (there is already a full fibreglass shell available), then what about a AM DB5/6, Dino, MK2 Jag, Fiat 500 (on Smart Fortwo running gear ?) and much more.

So what would you like printing off

[chairchild]

looks like it's been made with rather thick layers - so ugly as a feature of it being quicker/cheaper it would appear.

With enough space to fit a big enough "delta" style printer, and a material that's got a high enough melting temperature for surviving around the engine bay... anything is possible, from a decent sized shed!



Love the concept of this, and what it means for the future

[93fxdl]

Had a look around a mobile engineering display at the Scottish airshow on Sunday, some examples of printing were there. To say I was stunned would be an understatement, a ball of gears which all meshed and revolved and various titanium components, how some were made lost me, but some were made using powder and lasers. 3d printing is in its infancy but I cannot comprehend what the future holds, New materials and changes in designs could mean, not only panels but drivetrain and suspension components
Ttfn Glenn

[igor]

How about all those horrid trim clips that break if you look at them the wrong way and are similarly broken on all the parts cars you'll find?

[bazzateer]

One word, three letters.....................IMP

[mylittletony]

Most of it is material limitation as there is very little strength between the layers. Very good for making representations for mockup, but not much advantage over other methods for production quantities

If you want new body panels, you're better off getting the car 3D scanned, having moulds for each panel CNC cut from model board and laying up in GRP to take replicas.

Laser sintering as mentioned above is different, using the meeting of multiple lasers to melt the powdered material into solid. This can also use metal and is generally stronger than cast as less cavities, but weaker than billet or forging as there is no grain direction

[fireflyspeedshop]

Sept 11, 2015 2:01:17 GMT igor said:

How about all those horrid trim clips that break if you look at them the wrong way and are similarly broken on all the parts cars you'll find?

What he said^

[garethj]

I've used 3D printing to make 1:32 slot cars for the last 4 years. For bodyshells I get the 3D CAD data


and then stitch the surfaces together so the mesh is watertight. That means the surface data can then be 3D printed


This is where you need to know the limitations of the process; pretty much you can have fine detail or high strength. Fine detail also costs money, so for bodyshells it's just not cost effective to race the 3D printed parts. That's why I make a silicone mould and resin cast them, the model equivalent of fibrelgassing a replica for cost.

For the chassis, I designed it to have steering and suspension (because leaning and opposite-lock around corners is cool, right?) and then packed it all into the tightest space because the cost of the parts is the volume of it.


The parts get separated (like cutting them off an Airfix kit's sprue) and then built up




It all works like this


I'm harbouring an idea to scratchbuild a full size car but right now the problem is that 3D printed cost is down to the XYZ volume on the machine's bed. Even using it to make a mould to mould vacform or fibreglass parts is expensive for something like a wing panel.

A shame, because sending this to the printer is very appealing

[mylittletony]

^^^ that is the best thing I've seen in ages!

Where do you get the CAD files from? Been hunting for a Volvo 240 estate for a while...

[garethj]

Most of them are available to buy, type "Volvo 240 3D" into Google images and off you go. For a few I had to commission the 3D model to be made, it's more expensive but otherwise where are you going to get an Intermeccanica Apollo?

[mylittletony]

Once again, amazing!
Yes had seen the pricey versions but had no reports of the quality. + I'm a cheapskate
I'm off to dig out the scalextric.

[igor]

Very cool garethj.

[welshpug]

koenigsegg already make turbocharger housings and exhaust tailpipes with 3d printing.

look up the /Drive inside koenigsegg vids on YouTube

[skrapz]

That first one is a bit rough and ready on the other hand this Cobra...



Its electric too.

More info here..

www.digitaltrends.com/cars/shelby-cobra-replica-3d-printed-at-oak-ridge-national-lab/

[waveman1500]

Sept 12, 2015 9:46:38 GMT skrapz said:

That first one is a bit rough and ready on the other hand this Cobra...

By the look of the video and photos on their website, I would guess that the Cobra came off the printer looking almost as rough as the first car. The difference is plenty of man-hours sanding and painting.
In the photo below, you can see that the layers are huge, but it's been sanded and had the whole car skimmed with body filler to smooth it out. Which is fine, but it doesn't show off the capability of the printing technology.