Porsche 3D Printing Engine Piston Technology

[kobayashiGT]

Porsche 3D Printing Engine Piston Technology

 

 

3D printing technology is already used at Porsche in prototype construction, manufacturing spare parts for classic sports cars as well as in other areas. In cooperation with its partners Mahle and Trumpf, the sports car manufacturer is now establishing a new milestone in the use of additive manufacturing processes for highly-stressed drive components – for the first time, the pistons for the high-performance engine of the 911 flagship model, the GT2 RS, are now also being produced with a 3D printer. 3D printing allows the pistons to be manufactured with a structure that is optimised for the loads acting on the pistons. As a result, the pistons from the advance development project weigh ten percent less than the forged series production pistons. They also have an integrated and closed cooling duct in the piston crown that could not have been produced by conventional methods. “Thanks to the new, lighter pistons, we can increase the engine speed, lower the temperature load on the pistons and optimise combustion,” explains Frank Ickinger from the advance drive development department at Porsche. “This makes it possible to get up to 30 hp more power from the 690 hp twin-turbo engine, while at the same time improving efficiency.”

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Nice to know that the manufactuer is still innovating in combustion engine. 😁

 

[Sdf4786k]

in future, we just print our own spare parts.

Stockist jialat🙄 

[Watwheels]

After the print is done the piston still requires to be machined to its final tolerances. Actually the 3D print does what conventional casting methods cannot do like reducing some of the material that are not crucial to the structure. It also eliminates the chances of internal cavities forming during casting.

3D printing no matter how good cannot do a thousandth of a millimetre kinda tolerance. You still need to machine and grind the piston to that kinda precision. 

[Watwheels]

15 minutes ago, Sdf4786k said:

in future, we just print our own spare parts.

Stockist jialat🙄 

Maybe for plastic parts. Not likely for engine and gb parts.

[Sdf4786k]

6 minutes ago, Watwheels said:

Maybe for plastic parts. Not likely for engine and gb parts.

actually, quite current liao

https://markforged.com/metal-x/?mfa=sga-ap-mof-3dprintermetal&adg=102256407073&kw=metal 3d printing&device=c&gclid=Cj0KCQjw9b_4BRCMARIsADMUIypCf_gpVFOpaL_dSZN6DPkcMk31NPDFUlDAmw8zf1F1CVqzplkISEYaAk2aEALw_wcB

[Watwheels]

8 minutes ago, Sdf4786k said:

actually, quite current liao

https://markforged.com/metal-x/?mfa=sga-ap-mof-3dprintermetal&adg=102256407073&kw=metal 3d printing&device=c&gclid=Cj0KCQjw9b_4BRCMARIsADMUIypCf_gpVFOpaL_dSZN6DPkcMk31NPDFUlDAmw8zf1F1CVqzplkISEYaAk2aEALw_wcB

How much does the 3D printer cost?

It's not cost effective if an individual is buying the 3D printer to print his own car parts.

It's only cost effective for mass production. 

Edited July 17, 2020 by Watwheels

[Watwheels]

Parts like exhaust systems 3D printer cannot accommodate the length and certain size. Manufacturers still requires to buy the stainless steel pipe and bend it, weld the connecting flanges and bolt them together.

[Beregond]

i assume  'Thanks to the new, lighter pistons,' this will not last as long as the old heavier 1. if they are using same material😁

[Sdf4786k]

32 minutes ago, Watwheels said:

How much does the 3D printer cost?

It's not cost effective if an individual is buying the 3D printer to print his own car parts.

It's only cost effective for mass production. 

when laser printer started, it was like 5 to 10 K, Now its like a few hundred.

So would be in future, the cost will come down. 

Else, it will be like a printing shop in queensway. Provide the 3D and go with the mass printing route as you suggested.

What this will translate to more owners having a hands on approach to their cars as well as cars that are obsoleted like SAAB may have the ability to shorten the search for spares. 

I suppose can 3D print bumpers in future.  

Edited July 17, 2020 by Sdf4786k

[Watwheels]

12 minutes ago, Sdf4786k said:

when laser printer started, it was like 5 to 10 K, Now its like a few hundred.

So would be in future, the cost will come down. 

Else, it will be like a printing shop in queensway. Provide the 3D and go with the mass printing route as you suggested.

What this will translate to more owners having a hands on approach to their cars as well as cars that are obsoleted like SAAB may have the ability to shorten the search for spares. 

I suppose can 3D print bumpers in future.  

This is the thing ppl always get mistaken thinking high technology will dominate how we make and produce things in future.

Sad to say this is not the case. High technology is often associated with high cost. Why are some of the old methods are still widely used today is low cost. If low cost still get the job done, parts makers will still adopt it.

What limits 3D printers are their size. Longer parts or parts bigger than the printer itself it cannot be done. 

[Throttle2]

Very cool

[Wt_know]

my interest is 3d printing for car interior parts

like customizing button, knob, cover, handle, etc ... awesome

i believe local 3d printing cost is not very expensive

Edited July 22, 2020 by Wt_know

[Gnahp]

On 7/17/2020 at 9:30 AM, Watwheels said:

After the print is done the piston still requires to be machined to its final tolerances. Actually the 3D print does what conventional casting methods cannot do like reducing some of the material that are not crucial to the structure. It also eliminates the chances of internal cavities forming during casting.

3D printing no matter how good cannot do a thousandth of a millimetre kinda tolerance. You still need to machine and grind the piston to that kinda precision. 

agree with you but parts made from casting and forging also need machining to get to the final tolerance,  except for parts machined from billet