A Porsche enthusiast in Europe, with the assistance of a 3D printing service provider, used 3D scanning, modeling software, 3D printers and casting technology to create a Porsche 356 car engine model. Model design, component manufacturing and assembly processes are completed in a short time. 3D printing resin materials with different properties in the manufacturing process allow designers to have more flexible and diverse choices in manufacturing. In this issue, the editor will share the design and manufacturing process of this Porsche engine model.

The ratio of the 3D printed Porsche 356 engine model to the real engine is 1:4. When manufacturing, the designer first disassembled the Porsche 356 engine and scanned these parts one by one with the David Laser scanner. Then perform 3D modeling based on the scanned data. The software used by the designer is Rhino and Meshmixer.

The designer finally chose the Form 2 SLA 3D printer from Formlabs and its supporting resin 3D printing materials to manufacture engine model parts according to their own requirements in terms of cost and accuracy.

A total of three different resin 3D printing materials are used in the manufacture of the engine model. The parts that need to be fine-tuned and screwed in the final assembly are printed with transparent resin materials, while the engine bracket and belt are made of elastic resin materials. Printed. The material required for the support frame in the engine model is aluminum alloy. The designer uses a 3D printing investment + casting method to manufacture the part. The master mold for casting is printed with a special resin 3D printing material for casting. The master mold After the printout, the designer provided it to a local foundry factory to manufacture the aluminum alloy support frame.

The engine model includes a total of 250 parts, and the designer divided it into 5 batches for 3D printing, which took 45 hours in total. After the printing is completed, post-processing of the parts is required, including removing the support structure produced during the 3D printing process, refining the micro holes in the parts, and polishing and painting the printed parts. After finishing the post-processing, the designer spent 4 hours to complete the engine assembly.

The experience of Porsche car enthusiasts using 3D printing equipment to quickly manufacture car engine models can also be used for reference in the design and development of car manufacturers. In the research and development of automobiles, designers need to repeatedly verify the design schemes of new products. During the verification process, prototypes of new products are often produced. 3D printing technology has become an important tool for rapid product prototyping by virtue of its speed and cost advantages in small batch manufacturing. Some well-known international automobile manufacturing companies have applied a large number of 3D printing technology in the field of rapid product prototyping. For example, Ford has set up 5 3D printed prototype manufacturing centers around the world, which manufactures more than 20,000 component prototypes each year, and BMW’s Munich Research and Innovation Center produces approximately 25,000 3D printed component prototypes each year.

3D printing equipment manufacturers and material companies have developed a variety of printing materials for rapid product prototyping and small batch production. Take the resin 3D printing materials used in the manufacture of Porsche engine models as an example. Many 3D printing companies or material manufacturing companies, including Carbon 3D, Formlabs, MadeSolid, MakerJuice, and Plastic Technology, are fragile for the photosensitive resin for desktop 3D printing. The problem of easy breakage and cracking has led to the introduction of stronger and durable resins. Some resin materials can match the performance of ABS plastic injection molded parts. Some resin materials have achieved a balance between strength and elongation, making 3D printed The prototype product has better impact resistance and strength. In addition to hard resins, 3D printing companies have also introduced 3D printing resin materials for investment casting, as well as flexible or elastic resin 3D printing materials required for the manufacture of hinges and friction devices. The types of materials available for manufacturing users are becoming more and more abundant.