Prototyping in the automotive industry : tools made from plastic

Abstract

Main goal of my master thesis is the analysis of possible prototype/production methods for automotive components made from plastics or foam. The issue is the possible production of tooling realized by using 3D printing methods. There are some results on the market for small production series where plastic tools can be used2, but, there are no real information about production limits (as material, technology, quality or part number producible) and also design highlights or economic factors, are not available. However the usage of 3D printed tools are mentioned3 even for plastic molding. Because these technologies are very new, their possibility of usage in the actual products category has to be evaluated. The intended material to be produced can be in the category of plastics (thermoplastics, reactive materials), foams, rubber or composite materials. Production devices by using these tools are intended to be molding machine, RIM devices or even manual production devices. Supposing is that the 3D printed plastic material are suitable for tools used for prototype or low series part production. The prototype making concept is intended for small quantities (50-200 parts) products. As for our planning we intend to use a composite tool by having the form defined by the 3D precision printing and apply strengthening elements/layers for temperature and stress support wherever is necessary. The possibility of use, the main influencing factors will be analyzed and solution to apply in the mirror component production also will consider and, if possible, later implemented in practice. This Know-how and practice can be as well used, for other plastic or foam part production. The process is not intended in the first step to be used for mass production, but for premium vehicles where the necessary components are relative low in number, can be a real alternative. Actually, the tools we use usually are made of aluminum or silicon devices for this kind of prototype phase. Due to the fact that more individualized components came to market, the processes are intended to cover this business segment as well. For individual designed components or even single customer needs, the process can be adapted to offer to the company this kind of -specialized- components on affordable price. The tools made as usual by material removal (milling) are cost intensive and make no economic sense to be produced in such cases. The new method in research is to find the most economic and suitable tool material. This solution can be used for prototyping but no information is available about limits and needs. The methodology which will be research in this work can be a base for other companies as well with their specific requirements. If we want to compete Japan or Germany and the United states with commodities we have to be fast and creative in design/prototype phase. 3-D printing opens us thoughts on the development which were not there before - this also opens new ways in intelligent manufacturing. As an example based on valid experience: PORSCHE Spider is produced for 1000 cars on the entire life cycle. The production cost can be optimized for similar car segment. The main goal at the first stage is to reduce the time to market (for exhibitions or tests). As the mirrors can be individually designed and adapted even for single users, (embossed individualized logo on the mirror external surface), the importance of the technology can be seen significantly. 3D printing components can be realized but their strength does not fulfill yet the automotive needs for running in traffic. In order to understand better my work plan, in 1. Figure you can see the intended process flow for the master Thesis.