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Design for AM optimisation for automotive industry

THE CHALLENGE

Design SMEs GRM and K-Tech were keen to further investigate the capability of Additive Manufacturing (AM).

In order to fully utilise the benefits of AM for product improvement, GRM and K-Tech were looking to develop knowledge and expertise in considerations for Design for AM.

K-Tech had previously designed and manufactured a motorbike fork end, and were looking to improve this product.

MTC'S SOLUTION

Working with GRM using TruForm topology optimisation, the MTC facilitated fast iteration of designs to optimise the motorbike fork.

Two motorbike forks were manufactured in a titanium alloy using Electron Beam Melting (EBM).

The MTC performed non destructive evaluation (NDE) via structured light scanning. This was carried out using GOM for geometric conformance and X-ray computed tomography for defect detection.

THE OUTCOME

Electron beam additive manufactured components with assurance of quality via NDE.

Optimisation of component design, achieving a 50g weight saving per component. The switch to titanium improved fracture toughness.

BENEFITS TO THE CLIENT

Fast iteration and design change implementation throughout project.

Product and process knowledge captured for use in future GRM and K-Tech programmes.

Transferable capability and knowledge obtained as a result.

Created by Tian-Long 7 months ago (last activity 7 months ago) and viewed 91 times

Proof of Concept related to Prototyping in the context of Automotive

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