3 d printing poised to advance cleaner cars - scientific american
TRANSCRIPT
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 14
ADVERTISEMENT
Sign In | Register 0
Search ScientificAmericancom
Subscription Center
Subscribe to All Access raquo
Subscribe to Print raquo
Give a Gift raquo
View the Latest Issue raquo
Subscribe News amp Features Topics Blogs Videos amp Podcasts Education Citizen Science SA Magazine SA Mind Books SA en espantildeol
Rather than milling away a block of metal a printercreates a component from the bottom up adding toit layer by layer from a print head Photo courtesy of Oak Ridge National Laboratory
Technology raquo Climatewire
3-D Printing Poised to AdvanceCleaner CarsThe technology could help make more efficient cars more cheaply
January 29 2015 | By Umair Irfan and ClimateWire
Its rare that a gleaming azure legend onwheels fails to turn heads but at the Detroitauto show earlier this month Oak RidgeNational Laboratorys Shelby Cobra facedstiff competition for attention
Acura and Ford introduced their newsupercars while other automakerspresented nextshygeneration hybrids andelectrics Towering matte military fightingvehicles and shiny trucks vied for the eyes ofmore than 800000 attendees
But in this showcase all about the future ofthe auto industry the Oak Ridge Cobra a throwback to 1967 was a harbinger ofthings to come
The polished paint and chrome belied bodywork that came out of a 3shyD printermaking the roadster a victim of its own success
People would walk by it and say We dont get whats going on said Lonnie Lovegroup leader for the manufacturing systems group at Oak Ridge
It wasnt until Love placed a sign on the windshield saying Yes its a 3D printed carthat more people stopped to check it out
The project was a proof of concept showing the potential of additive manufacturing inthe automotive industry Rather than milling away a block of metal a printer creates acomponent from the bottom up adding to it layer by layer from a print head
Using these techniques automakers can cut development time shrink the carbonfootprint of their production cycle and tailor their vehicles for specific markets
We set out to develop technologies that could really push the envelope of a printedvehicle Love said
A fraction of the parts all of the speedOver the course of six weeks researchers printed the chassis and bodywork for theCobra from carbon fiber reinforced polymers While a production car can have more
Email Print
Follow Us
More from Scientific American
ADVERTISEMENT
Latest News Most Read
Smart Keyboard Gets A Charge Out of You
Every Life Has Equal Value (Part 2) Gates
Foundation CEO Dr Susan DesmondshyHellmann
Every Life Has Equal Value (Part 1) Gates
Foundation CEO Dr Susan DesmondshyHellmann
Regular Walking Can Help Ease Depression
Book Review The Powerhouse
More raquo
See what were tweeting aboutScientific American Contributors
lggreenemeier Smart Keyboard Gets ACharge Out of You sciam Tech podcasthttptcoVFtocKf3de8 minutes ago middot reply middot retweet middot favorite
sciam Can science help solve the remainingmysteries of DeflateGate httptco51i85DyUvt sciencehttptcozs9f5yUiKS36 minutes ago middot reply middot retweet middot favorite
sciamblogs The path of least resistancehttptcoQDZKvKkfvc1 hour ago middot reply middot retweet middot favorite
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 24
than 20000 parts the Oak Ridge roadster had fewer than 70 and weighs about 1600pounds
Literally you could put a whole new drivetrain in in a couple days Love said Thewhole car in terms of manufacture was extremely cheap The price tag came out toabout $14000 he added
Though the Oak Ridge Shelby Cobra traded the throaty rumble of a Vshy8 for the purr ofa 100shykilowatt electric motor it could still lay rubber going from zero to 60 mph inless than five seconds The motor drivetrain brakes and wheels came off the shelf
Its really exciting what Oak Ridge is doing because it shows us that we can take thisto a much larger level said Ellen Lee team leader for additive manufacturingresearch at Ford Motor Co Its really beautiful she said of the Cobra
Automakers have used additive manufacturing techniques in some form for the past30 years but printing was largely limited to oneshyoff parts used only in the design andprototype stage
Its really tough today to compete with manufacturing processes like injectionmolding and stamping Lee said Though the machines that produce parts like doorsbumpers and chassis take months to set up and cost millions of dollars they makecomponents in seconds which is essential for factories that crank out a halfshymillioncars at a rate of one per minute
Additive manufacturing on the other hand can take hours per part There are alsopotential structural problems Parts are printed in successive layers so they maywithstand stress in one dimension but fracture when bent a certain way
Shorter production time using less energyThe printing process also leaves ugly scalloped edges The Oak Ridge Cobra requiredextensive sanding and smoothing to match the curves of the classic
For a large manufacturer like Ford the value of 3shyD printing comes further upstreamin designing cars and the tooling needed to manufacture them
Rather than restructure an entire assembly line engineers can test fit parts in alimited production run fix problems and print again
By using these technologies in the prototypes phase you can iterate though designswithout changing the tooling said Harold Sears an additive manufacturing technicalspecialist at Ford
This speeds up the product cycle from something that spans years to a few monthsallowing new car designs to hit highways faster
In addition instead of competing with molds and stamps engineers can use 3shyDprinting to make the tooling itself Sears explained that much of the tooling used tomake car parts for a specific model is milled from steel and aluminum an expensivetimeshyconsuming energyshyhungry process For a prototype or a limited production carthis is overkill and it expands the energy footprint of a production line
With a 3shyD printer engineers can develop custom tools in hours designingcomponents with strategically placed internal pockets to reduce weight and theamount of material used something thats impossible to do with conventionalmachining processes Reducing the energy used in production creates a morefavorable footprint for clean technologies like electric and fuelshycell cars shrinking theenvironmental payback time
New automakers however are looking to take additive manufacturing furtherLawrence Gasman president of SmarTech Markets Publishing a 3shyD printingresearch firm observed that 3shyD printing lowers the barriers to entry for automotivesuppliers and companies building cars at smaller scales Its going to lure more
The SA Open Innovation Pavillion
Whole Youtrade Healthcare Innovations Reshyimagining Eye and Vision CareServices to Optimize Health amp Wellshy
being
See more projects and find out how to get involved raquo
Powered By
ADVERTISEMENT
Latest from SA Blog Network
Senators Vote in Circles about Global Warmingand the Keystone XL PipelineSTAFF Observations | 8 hours ago
Why We Need More Scientists in DavosGuest Blog | 8 hours ago
Beyond Oil Sands The Carbonates are ComingPlugged In | 10 hours ago
Jonathan Eisen and Jessica Richman on theMicrobiomeFood Matters | 10 hours ago
Rarely Seen Saharan Cheetah Revealed inIncredible PhotosExtinction Countdown | 11 hours ago
News From Our Partners
Regular Walking Can Help Ease Depression
New Skull Could Be from Human Group thatInterbred with Neandertals
Strange Comet Discoveries Revealed byRosetta Spacecraft
Big Gap Between What Scientists Say andAmericans Think about Climate Change
ADVERTISEMENT
ADVERTISEMENT
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 34
Share this Article
entrepreneurs into the business he said
Microfactories curbing expensesOne such company is Local Motors based in Phoenix Ariz The company printed itsown car the Strati on the floor of the Detroit auto show The company aims to buildcustomizable cars at microfactories around the country
Justin Fishkin chief strategy officer at Local Motors said his interest came fromwanting to build fuelshyefficient cars for climate changeshyconscious island communities
I couldnt find any auto manufacturer in the world interested in making 50000units he said The volume wasnt big enough for them It seems like a lot of cars tome but it didnt move the needle
Using crowdsourced designs the company aims to give car buyers more control overtheir vehicles Fishkin said he envisions a dealership resembling an Apple store wherea customer comes in picks the features he or she wants on a computer and then picksup the printed car the next day
This approach lets the company hedge between different clean technologies Whatwere doing with this digital platform is were allowing the consumer to choose whatfuel they want to run on Fishkin said
In a region like the Eastern Seaboard where electric vehicle chargers are moreprevalent a customer may select an electric drivetrain In an area with hydrogenstations a buyer may want a fuel cell Others may prefer a gasoline hybrid
Using 3shyD printing Local Motors can accommodate all of these choices withouthaving to build a massive plant for each version And with a microfactory in everyregion the transportation and delivery expenses of a car go down shrinking its carbonfootprint
When the car is traded in Local Motors can recycle it and give the customer a credittoward a new vehicle The company already has factories in Phoenix and Las Vegaswith planned facilities near Washington DC and Knoxville Tenn
Earlier this month President Obama announced that the University of Tennesseewould lead the Institute for Advanced Composites Manufacturing Innovation a $259million research consortium with 122 members including Oak Ridge Ford and LocalMotors (Greenwire Jan 9) The goal is to produce materials for lighter cars stifferwind turbine blades and cheaper gas storage tanks
As a result according to Oak Ridges Love interest in 3shyD printing is growing and thescience is rapidly advancing
Its a rocket taking off he said
Reprinted from Climatewire with permission from Environment amp EnergyPublishing LLC wwweenewsnet 202shy628shy6500
CommentsOldest shy Newest
You must sign in or register as a ScientificAmericancom member to submit a comment
Science Jobs of the Week
Research Technician (skeletal muscle disorders withhuman iPS cells)Johns Hopkins University Shcool of Medicine
Postdoctoral FellowStony Brook University
Postdoctoral scholar on energy storage eg Li ionbattery researchOkinawa Institute of Science and Technology GraduateUniversity (OIST)
More jobs from Naturejobscom raquo
Scientific American MindDigital
Get 6 bi-monthly digital issues+ 1yr of archive access for just $999
Hurry this offer ends soon gt
X
Next Article
New Technologies Track Our EyesmdashAnd Read Our MindsRead More raquo
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 44
YES Send me a free issue of Scientific
American with no obligation to continue
the subscription If I like it I will be billed
for the one-year subscriptionAdvertise
Special Ad Sections
SA Custom Media andPartnerships
Science Jobs
Partner Network
International Editions
Travel
Use of Cookies
About Scientific American
Press Room
Site Map
Terms of Use
Privacy Policy
Contact Us
Subscribe
Renew Your Print Subscription
Print Subscriber CustomerService
Buy Back Issues
FAQs
Scientific American is a trademark of Scientific American Inc used with permission
copy 2015 Scientific American a Division of Nature America Inc
All Rights Reserved
Subscribe Now
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 24
than 20000 parts the Oak Ridge roadster had fewer than 70 and weighs about 1600pounds
Literally you could put a whole new drivetrain in in a couple days Love said Thewhole car in terms of manufacture was extremely cheap The price tag came out toabout $14000 he added
Though the Oak Ridge Shelby Cobra traded the throaty rumble of a Vshy8 for the purr ofa 100shykilowatt electric motor it could still lay rubber going from zero to 60 mph inless than five seconds The motor drivetrain brakes and wheels came off the shelf
Its really exciting what Oak Ridge is doing because it shows us that we can take thisto a much larger level said Ellen Lee team leader for additive manufacturingresearch at Ford Motor Co Its really beautiful she said of the Cobra
Automakers have used additive manufacturing techniques in some form for the past30 years but printing was largely limited to oneshyoff parts used only in the design andprototype stage
Its really tough today to compete with manufacturing processes like injectionmolding and stamping Lee said Though the machines that produce parts like doorsbumpers and chassis take months to set up and cost millions of dollars they makecomponents in seconds which is essential for factories that crank out a halfshymillioncars at a rate of one per minute
Additive manufacturing on the other hand can take hours per part There are alsopotential structural problems Parts are printed in successive layers so they maywithstand stress in one dimension but fracture when bent a certain way
Shorter production time using less energyThe printing process also leaves ugly scalloped edges The Oak Ridge Cobra requiredextensive sanding and smoothing to match the curves of the classic
For a large manufacturer like Ford the value of 3shyD printing comes further upstreamin designing cars and the tooling needed to manufacture them
Rather than restructure an entire assembly line engineers can test fit parts in alimited production run fix problems and print again
By using these technologies in the prototypes phase you can iterate though designswithout changing the tooling said Harold Sears an additive manufacturing technicalspecialist at Ford
This speeds up the product cycle from something that spans years to a few monthsallowing new car designs to hit highways faster
In addition instead of competing with molds and stamps engineers can use 3shyDprinting to make the tooling itself Sears explained that much of the tooling used tomake car parts for a specific model is milled from steel and aluminum an expensivetimeshyconsuming energyshyhungry process For a prototype or a limited production carthis is overkill and it expands the energy footprint of a production line
With a 3shyD printer engineers can develop custom tools in hours designingcomponents with strategically placed internal pockets to reduce weight and theamount of material used something thats impossible to do with conventionalmachining processes Reducing the energy used in production creates a morefavorable footprint for clean technologies like electric and fuelshycell cars shrinking theenvironmental payback time
New automakers however are looking to take additive manufacturing furtherLawrence Gasman president of SmarTech Markets Publishing a 3shyD printingresearch firm observed that 3shyD printing lowers the barriers to entry for automotivesuppliers and companies building cars at smaller scales Its going to lure more
The SA Open Innovation Pavillion
Whole Youtrade Healthcare Innovations Reshyimagining Eye and Vision CareServices to Optimize Health amp Wellshy
being
See more projects and find out how to get involved raquo
Powered By
ADVERTISEMENT
Latest from SA Blog Network
Senators Vote in Circles about Global Warmingand the Keystone XL PipelineSTAFF Observations | 8 hours ago
Why We Need More Scientists in DavosGuest Blog | 8 hours ago
Beyond Oil Sands The Carbonates are ComingPlugged In | 10 hours ago
Jonathan Eisen and Jessica Richman on theMicrobiomeFood Matters | 10 hours ago
Rarely Seen Saharan Cheetah Revealed inIncredible PhotosExtinction Countdown | 11 hours ago
News From Our Partners
Regular Walking Can Help Ease Depression
New Skull Could Be from Human Group thatInterbred with Neandertals
Strange Comet Discoveries Revealed byRosetta Spacecraft
Big Gap Between What Scientists Say andAmericans Think about Climate Change
ADVERTISEMENT
ADVERTISEMENT
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 34
Share this Article
entrepreneurs into the business he said
Microfactories curbing expensesOne such company is Local Motors based in Phoenix Ariz The company printed itsown car the Strati on the floor of the Detroit auto show The company aims to buildcustomizable cars at microfactories around the country
Justin Fishkin chief strategy officer at Local Motors said his interest came fromwanting to build fuelshyefficient cars for climate changeshyconscious island communities
I couldnt find any auto manufacturer in the world interested in making 50000units he said The volume wasnt big enough for them It seems like a lot of cars tome but it didnt move the needle
Using crowdsourced designs the company aims to give car buyers more control overtheir vehicles Fishkin said he envisions a dealership resembling an Apple store wherea customer comes in picks the features he or she wants on a computer and then picksup the printed car the next day
This approach lets the company hedge between different clean technologies Whatwere doing with this digital platform is were allowing the consumer to choose whatfuel they want to run on Fishkin said
In a region like the Eastern Seaboard where electric vehicle chargers are moreprevalent a customer may select an electric drivetrain In an area with hydrogenstations a buyer may want a fuel cell Others may prefer a gasoline hybrid
Using 3shyD printing Local Motors can accommodate all of these choices withouthaving to build a massive plant for each version And with a microfactory in everyregion the transportation and delivery expenses of a car go down shrinking its carbonfootprint
When the car is traded in Local Motors can recycle it and give the customer a credittoward a new vehicle The company already has factories in Phoenix and Las Vegaswith planned facilities near Washington DC and Knoxville Tenn
Earlier this month President Obama announced that the University of Tennesseewould lead the Institute for Advanced Composites Manufacturing Innovation a $259million research consortium with 122 members including Oak Ridge Ford and LocalMotors (Greenwire Jan 9) The goal is to produce materials for lighter cars stifferwind turbine blades and cheaper gas storage tanks
As a result according to Oak Ridges Love interest in 3shyD printing is growing and thescience is rapidly advancing
Its a rocket taking off he said
Reprinted from Climatewire with permission from Environment amp EnergyPublishing LLC wwweenewsnet 202shy628shy6500
CommentsOldest shy Newest
You must sign in or register as a ScientificAmericancom member to submit a comment
Science Jobs of the Week
Research Technician (skeletal muscle disorders withhuman iPS cells)Johns Hopkins University Shcool of Medicine
Postdoctoral FellowStony Brook University
Postdoctoral scholar on energy storage eg Li ionbattery researchOkinawa Institute of Science and Technology GraduateUniversity (OIST)
More jobs from Naturejobscom raquo
Scientific American MindDigital
Get 6 bi-monthly digital issues+ 1yr of archive access for just $999
Hurry this offer ends soon gt
X
Next Article
New Technologies Track Our EyesmdashAnd Read Our MindsRead More raquo
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 44
YES Send me a free issue of Scientific
American with no obligation to continue
the subscription If I like it I will be billed
for the one-year subscriptionAdvertise
Special Ad Sections
SA Custom Media andPartnerships
Science Jobs
Partner Network
International Editions
Travel
Use of Cookies
About Scientific American
Press Room
Site Map
Terms of Use
Privacy Policy
Contact Us
Subscribe
Renew Your Print Subscription
Print Subscriber CustomerService
Buy Back Issues
FAQs
Scientific American is a trademark of Scientific American Inc used with permission
copy 2015 Scientific American a Division of Nature America Inc
All Rights Reserved
Subscribe Now
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 34
Share this Article
entrepreneurs into the business he said
Microfactories curbing expensesOne such company is Local Motors based in Phoenix Ariz The company printed itsown car the Strati on the floor of the Detroit auto show The company aims to buildcustomizable cars at microfactories around the country
Justin Fishkin chief strategy officer at Local Motors said his interest came fromwanting to build fuelshyefficient cars for climate changeshyconscious island communities
I couldnt find any auto manufacturer in the world interested in making 50000units he said The volume wasnt big enough for them It seems like a lot of cars tome but it didnt move the needle
Using crowdsourced designs the company aims to give car buyers more control overtheir vehicles Fishkin said he envisions a dealership resembling an Apple store wherea customer comes in picks the features he or she wants on a computer and then picksup the printed car the next day
This approach lets the company hedge between different clean technologies Whatwere doing with this digital platform is were allowing the consumer to choose whatfuel they want to run on Fishkin said
In a region like the Eastern Seaboard where electric vehicle chargers are moreprevalent a customer may select an electric drivetrain In an area with hydrogenstations a buyer may want a fuel cell Others may prefer a gasoline hybrid
Using 3shyD printing Local Motors can accommodate all of these choices withouthaving to build a massive plant for each version And with a microfactory in everyregion the transportation and delivery expenses of a car go down shrinking its carbonfootprint
When the car is traded in Local Motors can recycle it and give the customer a credittoward a new vehicle The company already has factories in Phoenix and Las Vegaswith planned facilities near Washington DC and Knoxville Tenn
Earlier this month President Obama announced that the University of Tennesseewould lead the Institute for Advanced Composites Manufacturing Innovation a $259million research consortium with 122 members including Oak Ridge Ford and LocalMotors (Greenwire Jan 9) The goal is to produce materials for lighter cars stifferwind turbine blades and cheaper gas storage tanks
As a result according to Oak Ridges Love interest in 3shyD printing is growing and thescience is rapidly advancing
Its a rocket taking off he said
Reprinted from Climatewire with permission from Environment amp EnergyPublishing LLC wwweenewsnet 202shy628shy6500
CommentsOldest shy Newest
You must sign in or register as a ScientificAmericancom member to submit a comment
Science Jobs of the Week
Research Technician (skeletal muscle disorders withhuman iPS cells)Johns Hopkins University Shcool of Medicine
Postdoctoral FellowStony Brook University
Postdoctoral scholar on energy storage eg Li ionbattery researchOkinawa Institute of Science and Technology GraduateUniversity (OIST)
More jobs from Naturejobscom raquo
Scientific American MindDigital
Get 6 bi-monthly digital issues+ 1yr of archive access for just $999
Hurry this offer ends soon gt
X
Next Article
New Technologies Track Our EyesmdashAnd Read Our MindsRead More raquo
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 44
YES Send me a free issue of Scientific
American with no obligation to continue
the subscription If I like it I will be billed
for the one-year subscriptionAdvertise
Special Ad Sections
SA Custom Media andPartnerships
Science Jobs
Partner Network
International Editions
Travel
Use of Cookies
About Scientific American
Press Room
Site Map
Terms of Use
Privacy Policy
Contact Us
Subscribe
Renew Your Print Subscription
Print Subscriber CustomerService
Buy Back Issues
FAQs
Scientific American is a trademark of Scientific American Inc used with permission
copy 2015 Scientific American a Division of Nature America Inc
All Rights Reserved
Subscribe Now
3112015 3shyD Printing Poised to Advance Cleaner Cars shy Scientific American
httpwwwscientificamericancomarticle3shydshyprintingshypoisedshytoshyadvanceshycleanershycars 44
YES Send me a free issue of Scientific
American with no obligation to continue
the subscription If I like it I will be billed
for the one-year subscriptionAdvertise
Special Ad Sections
SA Custom Media andPartnerships
Science Jobs
Partner Network
International Editions
Travel
Use of Cookies
About Scientific American
Press Room
Site Map
Terms of Use
Privacy Policy
Contact Us
Subscribe
Renew Your Print Subscription
Print Subscriber CustomerService
Buy Back Issues
FAQs
Scientific American is a trademark of Scientific American Inc used with permission
copy 2015 Scientific American a Division of Nature America Inc
All Rights Reserved
Subscribe Now