The document discusses the role of additive manufacturing in the automotive industry, highlighting its ability to facilitate the production of customized, complex, and lightweight components efficiently. Techniques such as selective laser sintering and selective laser melting are explored for their applications in creating various automotive parts, from engine components to interior accessories. The future of additive manufacturing in this sector is promising, enabling faster design and production processes while overcoming challenges associated with traditional manufacturing methods.

1. ADDITIVE MANUFACTURING
IN THE
AUTOMOTIVE INDUSTRY
PRESENTED BY :
SYED ZAYYAN ALI
4th YEAR
MECHANICAL ENGINEERING
MIT MORADABAD
GUIDED BY :
DR. MUNISH CHHABRA
HOD & PROFESSOR
MECHANICAL DEPARTMENT
MIT MORADABAD

2. ABSTRACT
Automotive industry faces new challenges every day, new design trends from research push
companies to develop new models in short term, requiring new tools. The automotive
industry is one of the most competitive business areas where time-to-market decrease plays
an important role. Additive manufacturing is the solution which enables the flexible
production of customized products without significant impact on costs and lead time.
Automotive companies developing new model every day, pushed by new design trends and
technological evolution where aesthetics, aerodynamics, safety, and weight reduction of the
vehicle are key issues. Therefore, Automobile manufacturers can increase the efficiency of
their research and development processes, enabling them to get their products on the market
with less time and efficiently.. An important parameter of using metal AM processes in the
automotive sector is fabricating complex lightweight structures which at the same time
possess good rigidity. The weight of the automotive parts can be reduced significantly by
using the ability of AM processes to maximum advantage to produce parts with complex
geometries while maintaining relative strengths.

3. INTRODUCTION
• Additive Manufacturing gives a new strategy to the modern challenges
going through the automobile industry. It gives design freedom while
permitting the advent of complex yet light-weight components. Additive
manufacturing is a disruptive and rapidly-growing technological that
permits designers to put together or rapid prototypes as nicely as
complicated designs, which in any other case would not have been
possible through legacy subtractive manufacturing processes. This
technology is additionally used for testing, manufacturing, and assembling
automotive components and factors with greater efficiency, optimization,
and cost-efficiency.

5. • In simplest terms, additive manufacturing is 3D
printing.
• This emerging manufacturing practice allows
researchers to create physical, three-dimensional
objects directly from a computer design file. It’s
similar to how common desktop printers form
images but instead of ink, 3D printers use a wide
variety of materials ranging from polymer
composites, metals and ceramics to food, foams,
gels, and even living tissue.

6. PROCEDURE OF
ADDITIVE
MANUFACTURING
• PART DESIGN
3D CAD MODEL
• TO .STL FILE
CONVERSION
• SLICING
PRE- PROCESS
BUILD PROCESS
PART REMOVAL
POST PROCESS

7. MAJOR ADDITIVE
MANUFACTURING
TECHNIQUE USED
IN AUTOMOBILE
INDUSTRY

8. SELECTIVE LASER SINTERING
The Ultimate 3D Manufacturing Solution Selective laser sintering is a
process that uses high-powered CO2 lasers to selectively melt and fuse
powdered thermoplastics. This process is ideal if you are looking to
produce tough, functional parts, with the possibility to achieve excellent
surface finish and fine detailing. SLS allows you to go beyond design
prototyping and achieve the highest accuracy, durability, and
repeatability with a low total cost of operations. SLS is also ideal for
complex geometries that would be difficult to produce using other
processes, or when the time and cost of tooling becomes prohibitive.
Engineers looking for functional parts and prototypes choose SLS as the
ultimate 3D printing technology for thermoplastic parts, without
compromise.

9. WORKING OF
SELECTIVE
LASER
SINTERING

10. SELECTIVE LASER MELTING
Selective laser melting (SLM), also known as direct metal laser
melting (DMLM) or laser powder bed fusion (LPBF), is a rapid
prototyping, 3D printing, or additive manufacturing (AM)
technique designed to use a high power-density laser to melt
and fuse metallic powders together. To many, SLM is
considered to be a subcategory of selective laser
sintering (SLS). The SLM process has the ability to fully melt
the metal material into a solid three-dimensional part unlike
SLS. A similar process is electron beam melting (EBM), which
uses an electron beam as energy source.

11. AM MATERIALS USED IN AUTOMOBILE
APPLICATION PROCESS MATERIAL PARTS
INTERIOR ACCESSORIES SLA NYLON CUSTOMIZED COSMETIC COMPONENTS
AIR DUCTS SLS RESIN FLEXIBLE DUCTING AND BELLOWS
FULL SCALE PANELS INDUSTRIAL SLA RESIN LARGE PARTS WITH A SURFACE FINISH
UNDER THE HOOD SLS NYLON HEAT RESISTANT FUNCTIONAL PARTS
BEZELS MATERIAL
JETTING
PHOTOPOLYMER END USE CUSTOMS BEZELS
COMPLEX METALS
COMPONENTS
DMLS METAL LIGHT WEIGHT FUNCTIONAL META PARTS

12. RISE OF ADDITIVE MANFACTURING IN
AUTOMOTIVE INDUSTRY

13. CURRENT USES OF
ADDITIVE
MANUFACTURING IN
AUTOMOBILE INDUSTRY

14. Exhausts and emissions: Aluminium alloys are typically used for this application, via selective laser melting to
create cooling vents.
Fluid handling: Selective laser melting and electron beam melting are utilized with aluminium alloys. These
techniques can be used to make pumps and valves within the fluid handling system.
Exterior: Using selective laser sintering, polymers are currently used to manufacture wind breakers and bumpers.
Interior and seating: Using polymers and the techniques of stereo-lithography and selective Laser sintering,
dashboards and seat frames could be manufactured.
Tyres, wheels and suspension: Aluminium alloys and polymers can be manipulated with the aid of selective Laser
sintering, selective laser melting and inkjet technology to create suspension springs, tyres and hubcaps.
Electronics: Selective laser sintering can be used on polymers to manufacture a range of delicate components
including parts which have to be embedded, such as sensors, and single part control panels.
Framework and doors: Selective laser melting can be used on metal compounds such as aluminium alloys to
create body panels, including framework and doors.
Engine components: Various functional parts of the engine can be made from metals such titanium and
aluminium allows when techniques such as electron beam melting and selective Laser melting are used.

15. INTERIOR , EXTERIOR , FRAMEWORK AND DOORS

16. BUGATTI - 3D PRINTED BRAKE
CALLIPER
3D PRINTED FUCNTIONAL
ALTERNATOR BRACKET

17. PLASTIC COMPONENT MADE FOR
FITTING OF ELECRTONIC PARTS
SAMPLE METAL 3D PRINTED
WATER CONNECTORS

18. FORD'S 3D PRINTED ALUMINIUM INLET MANIFOLD

19. CURRENT
AND
FUTURE

20. CURRENT STATUS OF
ADDITIVE MANUFACTURING
IN DIFFERENT INDUSTRIES
Ford Motor Company: It used to be returned in 1988; however a lot of
growth has been made seeing that then. Ford had invested $45 million in its
Advanced Manufacturing Center, devoted for developing and incorporating
3D printing and unique applied sciences to their manufacturing lines. Earlier
this year, Ford Performance, which is the excessive basic performance
division at Ford Motor Company, has printed what claimed to be the greatest
3D printed metallic auto section in history.
BMW: BMW is one of the early adopters of additive manufacturing that has
been experimenting with this science for a number of years. Since 2010, it
had already crossed the one million 3D printed components mark. As for
mass production, BMW is aiming for manufacturing of 50,000 aspects per
year and 10,000 spare parts. BMW has proven various success memories in
imposing printed metal parts to their vehicles. As for example, BMW chose
to utilize 3D printing in the manufacturing of two parts of its i8 Roadster.

21. Volkswagen: It has been using in-house 3D printing for a number of years,
putting in almost a hundred 3D printers in its factories to date. At
Volkswagen, additive manufacturing main utility is for application like
tooling, jigs & fixtures and prototyping. Almost all of its tooling
manufacturing has been switched and is based totally nowadays on 3D
Printing, saving the company hundreds of 1000$ each year since.
McLaren: McLaren Racing and Stratasys team up to carry additive
manufacturing to Formula 1. McLaren Racing will be receiving Stratasys
latest Fused Deposition Modeling(FDM)- and Poly Jetbased 3D printing
solutions and contemporary substances for visual and functional
prototyping, personalized production parts and production tooling together
with composite tooling, This will allow accelerated transport whilst
increasing performance and productiveness in McLaren’s design and
manufacturing operations.

22. CHALLENGES FOR AUTOMOBILE INDUSTRIES
OF ADDITIVE MANUFACTURING

23. CONCLUSION
This presentation aimed to discuss the scenario of additive
manufacturing in automobile industry. Additive Manufacturing is the
future of Automobile Industry, as some of the examples are discuss in
this presentation. In AM, CAD software’s can be used for optimizing the
manufacturing process of automobiles in the automotive industry.
Through the use of 3D technology, certain parts of vehicles such as the
Framework and doors, engine components, exterior, dashboard
components, among others, can be created with ease. Owing to its very
few challenges when compared to the numerous advantages it offers,
Additive Manufacturing can be considered a very effective technology.

24. THANK YOU.