Hybrid 3D Printing Approaches To Enhance Automotive Exhaust Manifold Capabilities

3D Printer Benefitting In Prototyping Process of an Automotive Exhaust Manifold

BigRep, Large-Scale 3D printer’s developer in Germany recently witnessed its STUDIO 3D printer playing a significant role in the prototyping of an automotive exhaust manifold. This was done as a part of research, the company had been carrying out with Polymertal, a highly-innovative company in Israel producing hybrid products. Both the companies are looking for more cost-efficient and faster ways for performing fit-form-purpose manifold testing. This is done for reducing costs as well as development time. Along with this, advancement in the mechanical properties of prototype is done for making it closely resemble the finished parts from the cast metal.

In order to cater to the prototyping process, a huge manifold was 3D printed with the help of BigRep STUDIO. This product was catered to the growing needs of customers demanding for compact size product with similar capabilities as the BigRep ONE. Along with cost-effectiveness, the product was taken up as a perfect model for prototyping automotive exhaust manifold. With the innovative technology of Polymertal, plating of 3D printed parts was done, thereby creating strong and light objects. Therefore, plating the exhaust manifold offers increased heat as well as chemical resistance with enhanced strength. Manufactured quickly as well as at low cost, mechanical properties of the part were similar to the finished part. This in turn makes it suitable for the real functional testing.

Hybrid Approach to Be Adopted By Emerging Automotive Manufacturers

Consequently, quality of parts and the manufacturing speed gave Polymertal and BigRep to take on the technique of metal plating and 3D printing for utility as faster and improved testing of the upcoming automotive component designs. Eyeing on this new development, manufacturers in the overall automotive industry are taking immense efforts in adopting this 3D printing prototypes, which offer cost and time savings on a major basis. This hybrid approach is expected to be highly beneficial for Polymertal and BigRep as it helps in producing prototype close to final part, thereby enabling cheaper and faster production along with effective testing.

New Engine Launch with Integration of Exhaust Manifold to Deliver Effective Cooling

The new 1.3-litre petrol engine of Nissan Qashqai consists of exhaust manifold that is partially incorporated in cylinder head for effective cooling of the exhaust gas as well as more effective combustion, especially at the high loads and low engine speeds. The high-efficient new engine is made available in 160 PS and 140 PS outputs, thereby delivering decreased fuel consumption as well as CO2 emissions. Three types of all-new 1.3-litre engine:

  • 160 PS seven-speed DCT
  • 160 PS six-speed manual
  • 140 PS six-speed manual

The highly improved petrol powertrain line-up holds an innovative standard for the drivability in Qashqai. Customers are likely to witness improved acceleration and response by means of advanced torque and power, linear and smoother power delivery as well as quieter driving experience. In addition to this, the new development enables in extension of service intervals as well.

Note: The all-new powertrains are in compliance with the novel emissions standard – Euro 6d-Temp.

Breakthrough Engine Technology to Drive Production Sales of All-New Infiniti QX50

The all-new Infiniti QX50 consists of the world’s first variable-compression ratio engine. VC-Turbo is a 2.0L turbocharged 4cylinder representing broader leap forward for the internal combustion engine technology. The new engine functions with compression ratio as less as 8:1 and high as 14:1 as well as holds the power to switch between regular and Atkinson combustion cycles. The main features of VC-Turbo:

  • Light-weight
  • Smaller
  • Fuel-efficient

VC-Turbo uses both direct and port fuel injection and consists of a normal single-scroll design holding integration of the exhaust manifold engine system in cylinder head. With the improvement in emissions, and the mounting of catalytic convertors next to turbo enables in quick increase of temperature.

All-New Upgraded Engine Enables in Enhancing Acceleration Performance

Picanto GT by Kia Motor Corporation in South Korea witnesses development of new equipment and engine upgrades. The new 1.0 T-GDi engine with 171Nm and 99bhp torque makes Picanto GT more powerful than ever before. The new development enables in accelerating upto 60mph in 9.8 seconds. The single-scroll turbocharger has been paired with the electric wastegate motor, thereby improving the overall turbocharger performance, and searching clean air for engines, benefitting in the re-use of the combustion purposes. This exclusive engine is integrated with an exhaust manifold in a single-piece casting, lowering the exhaust gas temperatures, reducing weight as well as improving sealing.

To avail further insights on recent developments in automotive exhaust manifold market, click here.

About Sandali 225 Articles
A former journalist, Sandali is a content marketer with over 5 years of writing experience, across various industries including Food Innovation, Healthcare, and IoT and Technology. Sandali has been weaving corporate stories for organizations through different forms of impactful marketing content. Her key aim is to strategically align well-crafted narratives with business objectives, translating into a powerful communications platform for the company.