MATERIALS
Additive manufacturing is a key enabler of more efficient EV components
AGILE AM FOR AUTOMOTIVE
How additive manufacturing with special thermoplastic composites is driving the automotive and transport revolution
T
he transportation industry is undergoing profound changes including a shift towards demanding electric
vehicle (EV) requirements, and more OEM manufacturers are being faced with the challenge of transitioning towards electric and new technology production lines. In this transformative landscape,
additive manufacturing (AM) has emerged as a key enabler, capable of addressing new demanding criteria. However, the success of this approach hinges on the meticulous selection of high-performance materials capable of meeting the functional and structural demands of critical components. Additionally, materials may need to be ESD compliant (minimising electrostatic discharge) to ensure safety and reliability in sensitive electronic environments. In other cases, they might need to exhibit marked dielectric properties to efficiently insulate and manage high-voltage components in EVs. Windform’s 3D composite range encompasses
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materials accomplishing such demanding criteria.
THE ADVANTAGES OF AM AM eliminates the need for traditional tooling, significantly cutting down initial setup times and costs. The process is inherently efficient, minimising material waste while maintaining the high precision required for complex components. This immediate production capability empowers companies to respond quickly to market demands and technological advancements. While upgradings in battery capacity
have been crucial in extending the range of EVs, optimising new vehicle efficiency remains a key focus in their development. As such, industrial 3D printing service provider CRP Technology has pinpointed three core aspects that significantly enhance vehicle optimisation: powertrain efficiency, retaining part resistance to harsh conditions, reduction of vehicle mass and aerodynamic drag.
HIGH-EFFICIENCY POWERTRAINS AND COMPONENTS The safety and adaptability of Windform Composites to demanding transport requirements stems from three decades of expertise in the challenging world of motorsport and hypercars, which serves as a rigorous testing ground where additively manufactured components are required to excel in both reliability and efficiency under extreme operating conditions. The readiness of the Windform
material range lies in its unique combination of properties, ranging from high strength and lightweight characteristics to resistance to extreme operating temperatures, corrosion, water and fluid ingress, even over extended periods of time and upon high speed and vibrations. These attributes enable the creation of highly efficient components for critical areas such as cooling systems and air intakes where thermal stability and resistance to fluid exposure are crucial, and the cooling section of
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