Presented By
Rajashekhar S Savadi

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Rapid Prototyping in automobile Industry
Introduction
 For example
…….Head light
Fault replacement (say 100 cars, 1 week or less)
Solution?
 Formula 1
 Parts directly fitted to cars
 Quicker modifications
 Reduced cost
 Assemblies of parts into single component
• Cooling Duct
cooling of electrical system
traditional method – immpossible with one piece
necessary because of packing problems in F1 car
Made from SLS nylon-12
Formula Student
 Annual racing competition since 2001
 Teams from worldwide universities
 If less time taken to manufacture then more time is left for design and optimisation
 Changes to previous yrs is easy …..
 Body work assembly
air intake manifold
 Around 28 body parts by SLA process
 Desire for low weight so less space for air intake manifold
 High temp around engine….
 SLS –more durable nylon
 7 parts by SLS
 1 by FDM
 air-conditioning system
History
 Present design using CAD
 Fluid flow analysis, FEM analysis
 Rapid prototyping --- CAM
 Prototype Automotive Gearbox
 Assembly of the rapid prototypeparts ready for fitting of theinternal mechanical parts
J H Automotive Services
 Client- Getrag Ford Transmissions
 2 prototypes.
 clients 3D CAD data
 Selective laser sintering(powder based) – ceramic mould
 prototype gearboxes of aluminium then CNC machined