Making Car Parts with a 3-D Printer

The New Technology

The article my friend sent me was a column by Frank Markus entitled “3-D Classes: Showing the Industry a New Way to Design and Build Cars” (Motor Trend, March 2017).

The article addresses the work of Kevin Czinger, who researched the environmental impact of gas and hybrid automobiles due to his concern for the planet. He found that manufacturing the vehicles and the fuel accounted for more than 75 percent of the vehicle’s environmental impact (according to Argonne National Lab’s life cycle GREET model data). So he began to look for alternatives to metal stamping and welding car parts.

Czinger therefore founded Divergent 3D in Gardena, California, where he uses “off-the-shelf carbon-fiber tubing and sheet goods,” along with 3-D custom printing, to create an auto chassis that is cheaper to manufacture and significantly lighter in weight than a traditionally produced product. It will “accommodate any type of body, powertrain, and feature content” (“3-D Classes: Showing the Industry a New Way to Design and Build Cars”).

According to the article, Czinger’s process for a “prototype Blade uses 69 nodes, each of which are 3-D printed by laser sintering powdered aluminum to connect an intricate web of carbon-fiber tubes and honeycomb-aluminum or carbon-fiber sheer paneling—all off-the-shelf commodity parts” (“3-D Classes: Showing the Industry a New Way to Design and Build Cars”).

(As a point of interest, laser sintering is one of a number of processes, including direct metal laser sintering, selective laser sintering, and electron beam additive manufacturing, that use a laser or electron beam to melt and fuse powdered metal or wire into a usable—and stable—3-D form, building up the substance layer by layer from a 3-D computer aided design model.)

Frank Markus’ article then notes the bottom line: a “drastic drop in manufacturing cost and complexity.” And, by inference, if there’s a drop in the complexity of manufacturing, there will be a lessened effect on the environment.