Porsche shows the potential of additive manufacturing for high-performance drives

Porsche shows the potential of additive manufacturing for high-performance drives

17.12.2020: Prototype for small-series production: electric drive housing from a 3D printer Lighter, more rigid, more compact: Porsche has produced its first complete housing for an electric drive using 3D printing. The engine-gearbox unit produced using the


Prototype for small-series production: electric drive housing from a 3D printer




Lighter, more rigid, more compact: Porsche has produced its first complete housing for an electric drive using 3D printing. The engine-gearbox unit produced using the additive laser fusion process passed all the quality and stress tests without any problems.




“This proves that additive manufacturing with all its advantages is also suitable for larger and highly-stressed components in electric sports cars,” says Falk Heilfort, Project Manager in the Powertrain Advance Development department at the Porsche Development Centre in Weissach. It is conceivable that the optimised electric drive could be used in a limited-edition super sports car, for example.



Engineers in the Advanced Development department were able to carry out several development steps at once with the prototype. The additively manufactured alloy housing is more lightweight than a conventionally cast part, and reduces the overall weight of the drive by approximately ten percent.

 

Thanks to special structures that have only become possible due to 3D printing, the stiffness in highly stressed areas has nevertheless been doubled. Another advantage of additive manufacturing is the fact that numerous functions and parts can be integrated. This considerably reduces assembly work and directly benefits part quality.



3D printing opens up new opportunities in development and manufacture of low-volume parts. Porsche is intensively driving forward the use of additive manufacturing for optimisation of highly-stressed parts. A few months ago, new printed pistons successfully proved themselves in the 911 GT2 RS high-performance sports car. The housing for a complete electric drive now developed also fulfils high quality requirements. In the same housing as the electric motor, the downstream two-speed gearbox is integrated. This highly integrated approach is designed for use on the front axle of a sports car.



“Our goal was to develop an electric drive with the potential for additive manufacturing, at the same time integrating as many functions and parts as possible in the drive housing, saving weight and optimising the structure,” says Falk Heilfort. No other manufacturing process offers as many possibilities and such fast implementation as 3D printing. Design data can be fed to the printer directly from the computer without intermediate steps such as tool making. The parts are then created layer by layer from aluminium alloy powder.

 

This makes it possible to manufacture shapes such as housings with integrated cooling ducts in almost any geometry. Every layer is melted and then fused with the previous layer. A number of different technologies are available for this purpose. The drive housing was manufactured from high-purity metal powder using the laser metal fusion process (LMF). Here, a laser beam heats and melts the powder surface corresponding to the part contour.



Optimisation of the electric drive started with the design integration of components such as bearings, heat exchangers and oil supply. This was followed by the computer-calculated definition of loads and interfaces. Determination of the load paths then took place on this basis. The next step in the virtual development method was optimisation of the load paths by integrating the so-called lattice structures.



These structures take their cue from nature, and can also be seen in similar form in bones or plants, for ex-ample. “We were able to expand and improve our software solutions and methods for creating such parts and are now able to virtually implement them in a very short space of time,” says Sebastian Wachter, Specialist in Design Methodology and Topology Optimisation in the Powertrain Advance Development department. When combined with artificial intelligence, interesting approaches for optimising development methods arise here for the future.



However, the extended design freedom offered by 3D printing also goes hand-in-hand with specific design requirements. These include the engineers having to take into account the fact that the work pieces are produced layer by layer by fusion. If there are large protrusions in the shape, supporting elements such as ribs may have to be planned. However, these must not extend into media-carrying ducts.



It is therefore important to already take into account the direction in which the layers are built up in the design phase. With the machine technology currently available, printing of the first housing prototype took several days and had to take place in two build processes due to the component size. With the latest machine generations, it is possible to reduce this time by 90 percent, and the entire housing can be manufactured in one build process.



The weight of the housing parts was reduced by approximately 40 percent due to the integration of functions and optimisation of the topology. This represents a weight savings of around ten percent for the entire drive due to the lightweight construction. The stiffness was increased significantly at the same time. Despite a continuous wall thickness of only 1.5 millimetres, the stiffness between the electric motor and the gearbox was increased by 100 percent due to the lattice structures.



The honeycomb structure reduces the oscillations of the thin housing walls and thus considerably improves the acoustics of the drive as a whole. The integration of parts made the drive unit more compact, significantly improved the drive package, and reduced the assembly work by around 40 work steps. This is equivalent to reduction in the production time of approximately 20 minutes.

 

 

An additional benefit: integration of the gearbox heat exchanger with optimised heat transmission improves the cooling of the drive as a whole. This is a basic requirement for further increases in performance.



The housing produced using the 3D printing process again shows the potential of additive manufacturing for Porsche when it comes to product innovation in the future. Potentials also arise in the areas of process innovation – agile development and flexible production – and for new areas of business such as customisation with new offers for customers and spare parts.

 

 

This manufacturing technology is technically and economically interesting for Porsche specifically for special and small series as well as motorsports.





Hermann-Josef Stappen- photos Porsche

Permanent-URL: http://www.automobilsport.com/porsche-additive-manufacturing-high-performance-drives---217529.html

17.12.2020 / MaP

More News

Race to Reality; Team Fordzilla’s Extreme P1 Virtual Race Car Make its Real World Debut
17.12.2020
•    Ford has brought to life a gamer-collaborated virtual car with a physical model•    Nearly a quarter of a million votes were submitted throughout the polling process•    Team Fordzilla P1 is Ford’s first ever car built digitally without any face-to-face interaction throughout the process more >>
Virtual reality and 3D scans: Digitally planned production of the Audi e-tron GT
17.12.2020
   Audi e-tron GT is the brand’s first model for which production planning was without any physical prototypes.        Audi develops VR software for planning and workshops in a virtual space      more >>
AWS and BMW Group Team Up to Accelerate Data-Driven Innovation.
08.12.2020
AWS and the BMW Group will jointly develop innovative cloud-enabled solutions and upskill up to 5,000 software-engineers in cloud technologies.Today, Amazon Web Services (AWS) and the BMW Group announced a comprehensive strategic collaboration. The goal of th more >>
Hyundai Motor Group’s Urban Air Mobility Vision Concept Named “Best Innovations in 2020” by Etisalat
06.12.2020
    Hyundai Motor Group is invited to exhibit its UAM S-A1 vision concept at GITEX    UAM augments urban mobility needs and shape society    Hyundai Motor Group presents its vision for a smart future mobility ecosystem which includes UAM, Purpose Built Vehicle and Hub more >>
Audi - New dimensions in lighting technology
04.12.2020
   Digitization of light opens up multi-faceted communication channels        Audi lighting technology combines exceptional design with high functionality        Close teamwork between Lighting Technology and Light Design as a success formula more >>
800 hours in pitch darkness to test the lights of the SEAT Leon
04.12.2020
    Alqueva, Portugal, one of the darkest areas in Europe, is the ideal place to test the lights developed by the SEAT Lighting Team    It took 800 hours in the dark to test the headlamps and rear lights of the new Leon    Their 100% LED technology opens up new possibilities for engineers in safety, c more >>
Cubic Telecom is First to Market with fully compliant global IoT software solution in Brazil for automotive and agriculture
04.12.2020
Cubic Telecom has expanded its global IoT software solution to Brazil by obtaining an Autorizada Licence and establishing a partnership with TIM Brasil, the leading Brazilian 4G network with nationwide coverage across 3,500 cities. Forging this strategic partnership with TIM Brasil, Cubic Telecom will extend its quality IoT solutions for global customers to Brazil - a country with the seventh l more >>
ENAIRE takes part in two European projects to promote future urban mobility with flying vehicles
03.12.2020
ENAIRE, Spain's national air navigation manager, is working on European projects to manage the future mobility of people in urban and suburban areas through flying vehicles, and air taxis in particular, as well as activities such as drone deliveries.So said ENAIR more >>
Siemens Energy and Porsche, with partners, advance climate-neutral e-fuel development
03.12.2020
• World’s first integrated commercial plant for producing climate-neutral fuel being built in Chile• Innovations from Germany to industrialize synthetic fuels and decarbonize the mobility sector• German Economy Ministry supports beacon project as part of national hydrogen strategy• Porsche is planning more >>
USTMA, The Ray and University of Missouri Announce Research Partnership
02.12.2020
Project to Assess Knowledge on Environmental Impact, Benefits of Rubber Modified Asphalt The U.S US. Tire Manufacturers Association (USTMA), in partnership with The Ray, a nonprofit proving ground for sustainable transportation technologies, today announced a resear more >>
New Acura Airbag Technology wins a Popular Science “Best of What’s New” Award
01.12.2020
    World’s first passenger front airbag designed to mitigate head trauma from angled frontal collisions debuted on the all-new 2021 Acura TLX sport sedan; will be standard on all-new Acura MDX three-row luxury SUV, on sale early next year    New Acura airbag tech was further recognized as the singular “Grand Award” more >>
Daimler's Lab1886 innovation forge to be reorganised
01.12.2020
    The main components of Lab1886 will be acquired by RB-Capital GmbH, majority-owned by GFT founder Ulrich Dietz. Daimler will hold a minority interest in the resulting 1886Ventures innovation platform. A further 10% of 1886Ventures will be held by the globally active software company GFT Technologies SE.    A substanti more >>
Audi is using augmented reality to increase efficiency in logistics planning
01.12.2020
Life size 3D holograms enable realistic visualization        Audi Board of Management Member for Production Peter Kössler: “Use digital technologies systematically” Audi relies on augmented reality more >>
SEAT invests more than 30 million euros in a pioneering southern Europe powertrain test centre
26.11.2020
    The facilities feature nine multi-energy benches that enable any type of engine to be tested, from the development phase to their homologation    From the Caucasus to Death Valley, in Martorell: a climatic chamber simulates extreme situations, with temperatures between -40 and +65 degrees and up to 5,000 m of altitude more >>
BMW Group founds company: IDEALworks GmbH to develop and distribute innovative robots and management software for logistics solutions
21.11.2020
• Further development and distribution of in-house developed Smart Transport Robot, STR • Next generation of STR to launch end of 2020The BMW Group breaks new ground in the field of logistics as it founds IDEAL more >>
Volvo Cars "ultimate driving simulator" uses latest gaming technology to develop safer cars
20.11.2020
Volvo Cars engineers call it “the ultimate driving simulator”, but it is not just an excuse for them to indulge their inner basement gamer. Instead, the Swedish company’s ground-breaking mixed-reality simula more >>
Hyundai Motor Group hosts 2020 Open Innovation Lounge featuring Inventive Startup Technologies
19.11.2020
    2020 Open Innovation Lounge selected startups via Hyundai Motor Group’s open innovation hubs, showcasing unique technologies to be used in future vehicles    11 startups from around the world displayed leading-edge solutions in vehicle entertainment, convenience and safety and hygiene    Hyu more >>
MINI Vision Urbanaut - Design issues, Concepts and Studies
17.11.2020
The MINI brand is using #NEXTGen to present, in a world exclusive, the MINI Vision Urbanaut – an all-new interpretation of a vision of space. This digital vision vehicle offers more interior space and versatility than ever before, but still on a minimal footprint. more >>
Jaguar Land Rover develops Smart City Hub to test self-driving vehicle technology
17.11.2020
   Future Mobility Campus Ireland (FMCI) collaboration will allow real-world trials       Facility will provide research opportunities for autonomous, connected, electrified and shared vehicles   more >>
Hyundai Motor Group Announces ‘2020 ZER01NE Accelerator’ Open Call to Collaborate with Startups
16.11.2020
    2020 ZER01NE Accelerator open innovation platform facilitates collaboration among startups and Hyundai Motor Group teams on future technology projects    Applicants can submit under 10 tech themes from November 16 to December 27 more >>
Experts discuss future mobility at the digital MQ! Innovation Summit
12.11.2020
MQ! Innovation Summit: digital for the first time        Board Member for Personnel, Sabine Maassen: “Making ideas into reality, between challenges and opportunities”        Digital discussion forums give depth to keynote speakers’ diverse views of future mobiliasty more >>
Industry Insights − The Facts And The Fiction of 5G
11.11.2020
As the roll-out gathers pace, 5G ultra high-speed broadband is swiftly becoming a reality for businesses. Yet there are many myths surrounding the technology that have been perpetrated and spread on social media. In this 'Industry Insights', we are looking at what’s real, what’s hype and what’s fake. more >>
The Electrified Wingsuit by BMW i - Leaping into a new dimension
11.11.2020
BMW #NEXTGen 2020When visionary power is brought together with innovative spirit, great things can happen – like the leap into a new dimension with The Electrified Wingsuit by BMW i. Following three years of prepara more >>
Virtual to Reality: How Ford Turns Data Into the Vehicle on Your Driveway
10.11.2020
•    Ford’s investment in simulations and simulators around the world has been revolutionizing the way they have been developing vehicles in recent years   •    The South African bui more >>
Hyundai Motor Group to launch NVIDIA DRIVE ‘connected car’ infotainment and AI platform across all future Hyundai, Kia and Genesis models
09.11.2020
    All new models from Hyundai Motor Group brands to feature NVIDIA DRIVE platform as standard, starting from 2022    NVIDIA technology enhances new connected car operating system (ccOS)    ccOS developed in-house by Hyundai Motor Group for all future models    Offers more >>
The first electrified wingsuit flight, powered by BMW i.
06.11.2020
Electric mobility by BMW i is conquering the third dimension. Within the framework of the #NEXTGen 2020, the BMW Group will present the first electric drive system for a wingsuit with which the centuries-old dream of flying can be realised in a completely novel way. The innovative drive module and the likewise entirely newly designed wingsuit were more >>
The BMW Group is presenting #NEXTGen 2020 digitally
03.11.2020
...at https://www.bmw.com/NEXTGen : Digital, innovative, different    The BMW Group’s #NEXTGen 2020 platform will present the development of the new BMW iNEXT as it progresses t more >>
Hyundai CRADLE’s MIF 2020 Brings Innovators Together for Virtual Forum on the Future of Mobility
31.10.2020
    The 5th Mobility Innovators Forum (MIF) brought distinguished thought leaders together to discuss how to turn the vision of human-centered mobility into reality    Anyone who missed the livestream can watch all sessions via the MIF website more >>
First digital MQ! Innovation Summit in 2020
29.10.2020
The fourth MQ! Innovation Summit on November 10/11, 2020        Digital exchange with experts on the mobility of the future        Register at www.the-mobility-quotient.com more >>
5G Automotive Association Virtual Showcase Highlights Momentum behind C-V2X Technology Deployment for Connected Vehicles and Smart Cities in the U.S.
28.10.2020
Leading automotive, tech and telecom companies combine efforts to accelerate Cellular Vehicle-to-Everything roll-out and increase  safety for drivers, pedestrians, and cyclists across the United  States. The 5G Automotive A more >>
Foam and rice for more sustainable cars: SEAT reveals its most innovative proposals during Innovation Day
28.10.2020
    Using a hybrid format, the company unveiled some of the ideas, visions and projects that promise to be the future of the industry       The new proposals presented internally focus on aspects s more >>
How Huawei is accelerating digital transformation to support today’s smart airports
28.10.2020
Huawei offers a comprehensive transportation solution, which leverages ICT technologies to digitize all transportation elements In this special interview, DeeDee Doke, head of content production at Airlines. mag more >>
The recyclable microfiber Dinamica® provides sustainable luxury for automotive interior surfaces
27.10.2020
Tightening environmental regulations are challenging the automotive industry. Dinamica®, a sustainable and recyclable premium microfiber suede is providing comfort and luxury while supporting the automotive OEMs to achieve their ambitious environmental goals more >>
Innovation Day - Cars parts made from rice husks? SEAT is already researching it
26.10.2020
    SEAT launches a pilot test to produce parts using rice husks       The prototypes are SEAT Leon trim elements made with Oryzite, a renewable and sustainable material    This circular more >>
SEAT rolls out its first mobility platform developed by SEAT:CODE
26.10.2020
    For the first time, the carmaker develops and markets a software rather than a hardware product    SEAT makes this technology available to other businesses and external operators, both public and private    Best Innovation and Transformation Project award and CIO of the year by CIONET more >>
Hyundai CRADLE to Host Mobility Innovators Forum 2020 to Turn Human−centered Mobility into Reality
23.10.2020
    The fifth Mobility Innovators Forum (MIF) will be hosted virtually on October 29-30    MIF 2020 brings thought leaders together from around the world to discuss the potential of human-centered mobility under the theme of ‘From Vision to Reality’    Anyone interested in joining the MIF more >>
First of its kind and innovation driver for sustainable mobility
19.10.2020
Production anniversary at the BMW Group plant in Leipzig - The first purely electrically powered large-scale serial production model of the BMW Group is still enjoying strong demand even after almost seven years of production.. more >>
How to Prepare IP Network Infrastructure for 5G Era
19.10.2020
As the world is gradually shifting to the new age of wireless, companies will need to adapt their current network infrastructure to attain the promise of near-zero latency and uncompromised reliability of connections. The long-awaited arrival of 5G comes w more >>
Mahle to push ahead with future technologies
18.10.2020
    Group maintains R&D investments at high level despite crisis    Expansion of global competence centers will further strengthen research and development    R&D activities to focus on solutions for battery systems and hydrogen applications    Installation of new hydrogen testi more >>
2001-2021 copyright automobilsport.com