NEWS MARKET OVERVIEW
However, via its subsidiary Audi, Volkswagen is taking part in the race. According to Alois Brandt, Head of Technology Development Innovation Management, the Group has evaluated ways to print metal car parts in low volumes. For him, there is still a long way to go before the technology can support a high rate of throughput. “For the Audi A4 for example, we would have had to install more than 1000 printers and run them at maximum speed only to end up manufacturing parts that would have been more expensive than with the current process.” Audi considers that 3D printing is mainly worthwhile for manufacturing tools and small production series. For now, 3D manufacturing is still slow and expensive and it is also limited in terms of the dimensions of the parts produced. The largest of the three printers in Audi's 3D metal printing centre can build parts of up to 400 mm in length. It takes a whole day to manufacture a metal tube weighing about 1 kg and added to this is the time needed to program and prepare the machine as well as the subsequent finishing operations. The 3D metal printing centre therefore focuses on the production of steel and aluminium tools from metal powder using laser fusion. Nevertheless, Audi expects that rapid advances in this technology in the years to come will make it potentially more attractive for manufacturing parts for limited series vehicle models. While waiting for the technological breakthrough, they are building up their know-how in the area of aluminium printing. Several car parts have been manufactured, such as components with porous structures that incorporate fluid reservoirs as well as the first suspension components.
© Stefan Warter
MORE INFORMATION
Z-brace for an Audi Space Frame of the future. It displays all the strengths of the technology – it is extremely complex, very lightweight and exceptionally strong.
13 | Industry EMEA | February 2018
8