02.09.2020
Author: Julia Rodenbücher, Marketing, toolcraft AG, Georgensgmünd
toolcraft AG is a pioneer in forward-looking technologies such as additive manufacturing and the construction of individual turn-key robot solutions. In engineering, it tests innovative processes and makes them ready for series production.
Description of the component:
In the project of High-Octane Motorsports e.V. and toolcraft AG, engine mounts, i.e. engine holders, were produced using additive manufacturing for an innovative racing car for the Formula Student. The brackets precisely define the position of the combustion engine.
Challenges:
In motorsport, every gram can make the difference between victory and defeat. In order to optimize the 3D printing process from design to production and post-machining, toolcraft used the NX software package from Siemens - including the modules for FEM calculations and topology optimization. To achieve maximum weight reduction, material was removed from areas of the components that are subject to low stress. By using a Ti6Al4V alloy with low material density and high strength, the high demands of motorsport were met.
Solution:
The solution consisted of a lean process chain: from data preparation and design to simulation and build job preparation for the 3D printing process. This made it possible to obtain reliable results in a short time, reduce the mass by almost 50 percent, guarantee the fatigue strength of the motor mounts and improve performance. Companies in all industries that are faced with challenges such as weight reduction and topology optimization can benefit from such an approach.