Audi manufactures a scale replica of the Auto Union Typ C using a 3D printer

Auto Union Typ C

The growing potential of 3D printing is undeniable, and when applied to prototype development or even to manufacturing real, functional cars, it is becoming increasingly common. It is a technology that has been used for many years, but thanks to improvements in new printers and the variety of materials they can use, it is being used more and more. This saves costs and produces prototypes more quickly than conventional processes.

Audi has used 3D printing to manufacture an exact replica at 1:2 scale of the 1936 Auto Union Typ C. This historic Grand Prix car was developed thanks to new production processes that have explored the limits of applying metal 3D printing, which the Ingolstadt brand intends to incorporate into its serial production processes.

The manufacturing departments of the Volkswagen Group work jointly on research and development, whose primary goal is the implementation of metal 3D printing and sand-based 3D printing in its production processes.

To carry out metal 3D printing, a sintering laser melts layers of metal powder with particles measuring 15 to 40 thousandths of a millimetre. This process enables the production of components with complex geometries, something that would be more difficult with conventional processes.

Steel and aluminium components can be obtained with a length of 240 millimetres and a height of up to 200 millimetres. The density achieved by these parts was much higher than that of parts produced by die casting or hot moulding.

The tool-making department of Audi (Toolmaking) stands out for its inclusion of smart tools used to achieve the greatest precision in the contours of the metal parts used in bodywork manufacturing. Corrective measures in the use of the laser for control of stamping processes are another of the innovations within the Volkswagen Group.

Source | Audi