Assessing the Use of Production-Rate Metal Additive Manufacturing for the Automotive Sector

Research Group Activity

Additive Manufacturing Group, Centre for Imaging Metrology and Additive Technologies, WMG

Project Description

Autosports dampers and actuators are highly complex products but they are in a highly competitive industry sector, and therefore there is a constant need for damper system developers to innovate their products. Recently, WMG has helped R53 Engineering, an OEM of high-end automotive dampers, to develop lightweight efficient dampers through the use of metal Additive Manufacturing (AM) technologies. This was successful in demonstrating the benefits that could be achieved over traditional manufacturing technologies, but, due to the low productivity of the chosen AM technology (Laser-Powder Bed Fusion), the capability is not suitable for higher volume production. R53 Engineering is now looking for new opportunities to take this capability to higher volume manufacture, and, due to the recent development of higher productivity, and production rate metal AM technologies, such as Desktop Metal binder jetting, this may now be possible. This project, working in collaboration between R53 Engineering, Desktop Metal, and WMG, will assess the technical capability of the new technology (Desktop Metal Shop System) for the manufacture of hydraulic actuator components. The project will involve: 1. The manufacture and microstructural and mechanical testing of samples to establish the capability of the DM Shop system, and determine the mechanical properties to enable the design of hydraulic components to a performance specification. 2. Determine the design limits (e.g wall thickness, hole diameters, etc) of the Desktop Metal Shop System through the manufacture of samples and their analysis. 3. Working with R53 and Desktop Metal to design hydraulic components within the manufacturing design limits, analyzing their quality, and assisting R53 in their validation. 4. Writing reports at each stage detailing the test methods, results, and conclusions.

Student Level

Open to both undergraduate and postgraduate students

Location

This project requires attendance at a lab or office on campus

Skills you can learn from this project

Knowledge of metal additive manufacturing technologies, automotive actuator design and function. Mechanical testing methods (hardness, tensile, flexural). Microstructural analysis methods (SEM, EDX, XRF etc). Design of experiments and experimental design methodologies, statistical analysis of data (e.g ANOVA). Collaborative skills, presentation skills, and report writing skills.

Required Skills

No requirement.

If you wish to apply for this project, fill in the form below including uploading your CV and personal statement, explaining why you want to do this particular internship project. Attachments must be in PDF format.

Project Team

Dr Bochuan Liu

Prof Greg Gibbons