Oil Intake Manifold
Wipro 3D delivers flight-ready components engineered for extreme temperatures, launch forces, and weight-critical missions.
CATEGORY
Industrial
MATERIAL
AlSi10Mg
In the highly competitive auto industry, speed to market, high strength to weight ratios, fuel efficiency are some of the few goals that constantly drive engineers and designers. New high-strength steels, along with composites and adhesives, are helping to reduce weight and increase strength in modern vehicles. Additive Manufacturing using metal alloys, has found interesting applications in tooling, jigs and fixtures, and design prototypes allowing companies to iterate rapidly and validate designs of components and subsystems. While metal Additive Manufacturing of co components at the production scale of automotive may be challenging, there are certainly emerging applications in the low volume, higher end of the industry including Formula 1 and military vehicles.
Additive Manufacturing allows optimizing the maximum strength with minimum weight and material (Topology Optimization) owing to the potential to handle complex geometries. "Monolithizing" sub-components or child parts into a monolith assembly reduces production time, improves functional performance. Typical applications of Metal AM in Automotive are weight optimized manifolds, turbine housings that form part of the current turbo powertrain ERS systems, water-wheel pumps , aluminum axle pivots. A leading name in industry has developed rocker arms and camshaft bearing caps using Metal Additive Manufacturing for its next generation truck engines.
About the Project
AM Competencies Used
Additive Design & Engineering
Wipro 3D used its extensive experience in Additive Design of various flow components to improve the channel design while retaining its functionality.
Post Processing
Post processing including powder recovery is extremely challenging in complex flow channels. Wipro 3D has delivered the project with successful strategies in these areas.
Build Technology
An entirely new set of customized parameters specific to the Manifold were evolved. Preliminary testing of the flow channels was performed on the Manifold.
AM Value Addition
Cost Of Iteration
Time-to-realize
The entire set of components was turned around in a period of one week, with the requisite mechanical properties, tolerances and finish, allowing designers to rapidly move to the design validation and improvement stage.
Other Case Studies
Receiver & Transmitter Antennae
The defence industry is among the earliest adopters of Additive Manufacturing along with the Aerospace industry, in a myriad of applications State run defence agencies and private defence organizations are using AM in highly critical projects for missiles, fighter jets, customized equipment, handheld weapons, drones, respiratory gear, and much more. The defence logistics and product acquisition Th processes are already in the process of transformation with the help of relatively small and tactical AM centers deployed in army, naval and air force establishments. Perhaps the most impactful application of AM could be portable in-field AM centers deployed near conflict zones.
Closed Impeller
Additive Manufacturing is reaching outer space. With increased effectiveness and maturity of space programs all over the world, leaders in the space community, are innovating, developing and iterating on multiple frontiers that lead to faster and cheaper deployment of payloads . The Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles to meet such requirements.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
North West Feed Cluster 2x2
Additive Manufacturing is reaching outer space. Where every gram counts, in an environment with extreme cyclic temperature variations and harsh forces during the launch, the functional life of components is a critical part of design considerations. Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
Bracket
The Aerospace industry has been at the forefront of adapting Metal Additive Manufacturing (AM) and some of the most evolved applications of metal AM can be found in the aerospace sector. Leading OEMs, tier 1 suppliers, and key ecosystem players are in the phase of developing mature capabilities in metal AM.
Typical value contribution from Metal Additive T Manufacturing comes in form of weight reduction, reduction in sub-assembled parts by creating monolithic designs, ability to realize complex designs and drastic reduction in lead time to realize components.
High Pressure Compressor Stator
The Aerospace industry has been at the forefront of adapting Metal Additive Manufacturing (AM) and some of the most evolved applications of metal AM can be found in the aerospace sector. Leading OEMs, tier 1 suppliers, and key ecosystem players are in the phase of developing mature capabilities in metal AM.
Typical value contribution from Metal Additive T Manufacturing comes in form of weight reduction, reduction in sub-assembled parts by creating monolithic designs, ability to realize complex designs and drastic reduction in lead time to realize components.