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3D printing

53-year-old Gerrit Braun and his twin brother, Frederik, founded Miniatur Wunderland in Germany’s Hamburg Speicherstadt district 20 years ago. It’s an exhibition space which measures more than 10,000 square metres in size and visited by around 1.4 million visitors a year.

If you have the time to count them, there are 9,250 cars, 269,000 figures, 15,715 metres of track, 1,040 trains with more than 10,000 carriages, 4,340 buildings and 130,000 trees. You’ll find cities, villages, mountain panoramas, an airport, artificial northern lights, and even a fair. It took over 300 employees who spent around one million hours to create this miniature world.

Miniatur Wunderland in Germany

Miniatur Wunderland in Germany

Miniatur Wunderland in Germany

The scale of the models is 1:87 and many of them are Porsche sportscars, including the 99X Electric which was added recently. But unlike other miniature worlds, there will be cars that not just move but also race – just like the real thing, only smaller.

Project started in 2015
The motorsport project has been ongoing since 2015 and it’s their biggest challenge to date. It encompasses the redesigned south of France, which will officially open in the first half of 2022, and features the legendary Monaco Grand Prix course.

“We’ll alternate between Formula One and Formula E races,” said Braun. “Everything true to the original, with parade lap, safety car, starting grid – and then action!”. For visitors to have the perfect view of all the racing action, the Miniatur Wunderland team first had to shrink Monaco. Like everything else, the principality on the French Riviera was reproduced at a scale of 1:87. The racing cars are just 6 cm long and their top speed of 85 cm per second would translate to nearly 270 km/h in the real world. This is as realistic as it gets – but that’s also what makes the whole undertaking so difficult.

Miniatur Wunderland in Germany
One of the sections of the Monaco circuit.

A scenario never built before
A small-scale scenario this realistic has never been built before. Everything had to be created from scratch. The software responsible for controlling 20 racing cars was developed on their own computer. The system responds to the driving manoeuvres of the other racers within 50 milliseconds, so each race is different. With real battles for position, passing manoeuvres, and occasionally even a crash. “Of course, we want to avoid that, if at all possible, because then the Safety Car has to come out and a couple of people are kept busy for some time,” Braun said.

While the race simulations are already running in the computer, Braun still has to teach the cars to accelerate at just the right moment. “The software always wants to maintain the lead, but sometimes you just need to slow down during a race. Programming all that is a complicated process,” he explained.

Miniatur Wunderland in Germany

The small electric cars are powered by magnetic fields. The 21-metre course through miniature Monaco is made up of 24 special circuit boards with a total of 1,400 magnetic field sectors, each of which is controlled separately and generates its own magnetic field.

3D-printed racing cars
While the software still needs some work, the racing cars are ready to race. They were created using the model building experts’ 3D printer and sheets of plastic just 0.03 mm thick. 3D data comes from companies like Porsche Motorsport which provided data for the 99X Electric used in Formula E.

Miniatur Wunderland in Germany

Miniatur Wunderland in Germany

The chassis are painted over multiple times and faithfully reproduced down to the smallest sponsor stickers to reflect their full-size counterparts. The underbody conceals a Halbach array, a diamond-shaped panel that serves as the counterpart to the magnetic fields along the course.

If everything goes according to plan, the miniature car races will be the Hamburg team’s next global milestone in the field of model building. “The crowning achievement of all our efforts,” said Braun. “Even more complex than the airport with its airplanes taking off and landing, which was commissioned in 2011.”

Miniatur Wunderland in Germany

Time cannot be shrunk
The fact that the masterminds of miniaturization have been working on the ambitious idea of a real racecourse for 6 years demonstrates their passion as well as the sophistication of the project. But Braun reveals one unsolvable problem with miniaturization: “We may be able to shrink down objects, but we can’t shrink down time.”

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Seating is an important aspect of driving and especially with sportscars, properly designed seats are vital for car control and comfort as they enable the driver’s body to be positioned correctly. Porsche will soon revolutionise sporty seating with an innovative alternative to conventional bucket seat upholstery with the concept study ‘3D-printed bodyform full-bucket seat’.

With this new technology, the sportscar manufacturer is once again underlining its close ties to motorsports. In this case, the personalised sports seat follows the principles of driver-specific seat fitting customary in professional motorsports.

Porsche 3D-printed bodyform full-bucket seat

In this study, the central section of the seat – in other words, the seat and backrest cushions – is partly produced by a 3D-printer. Customers will be able to choose between three firmness levels (hard, medium, soft) for the comfort layer.

“The seat is the interface between the human and the vehicle and is thus important for precise, sporty handling. That’s why personalised seat shells customised for the driver have been standard in racing cars for a long time now,” said Michael Steiner, Member of the Executive Board for Research and Development at Porsche. “With the ‘3D-printed bodyform full-bucket seat’, we’re once again giving customers the opportunity to experience technology carried over from motor sports.”

Close-up of the 3D lattice structure
Close-up of the lattice structure

In addition to an ergonomic fit similar to that found in racing cars, this seat also delivers a unique design, lower weight, improved comfort and passive climate control. The 3D-printed bodyform full-bucket seat is based on the lightweight full-bucket seat from Porsche and features a sandwich construction.

This consists of a base support made from expanded polypropylene (EPP) is bonded to a breathable comfort layer consisting of a mixture of polyurethane-based materials made using additive manufacturing – in other words in a 3D-printer.

The outer skin of the concept seat is made from Racetex and features a specific perforation pattern for climate control. Window panels provide a view of exposed coloured components in the 3D-printed lattice structure and give the full-bucket seat a distinctive design.

Porsche 3D-printed bodyform full-bucket seat
Visible components of the comfort layer

The 3D-printed bodyform full-bucket seat will be available from Porsche Tequipment as a driver’s seat for the 911 and 718 ranges from May 2020. The range will initially be limited to 40 seat prototypes for use on racetracks in Europe in combination with a 6-point seatbelt.

Feedback from customers will be incorporated into the development process. As a next step, street-legal 3D-printed bodyform full-bucket seats in three different firmness levels and colours will be available ex-works from the Porsche Exclusive Manufaktur from mid-2021.

Porsche 718
The new seats will be available for the latest 718 (above) and 911 models.

In the long-term, the technology will also enable fully personalised solutions if sufficient customers express an interest in this. In addition to an extended range of colours, seats adapted to the individual customer’s specific body contour will then also be developed and offered.

Visit www.porsche.com.my to know more about the latest products and services available in Malaysia.

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It’s one of the worst experiences for a driver – finding their car up on blocks (or sometimes not even off the road) with all four wheels gone. Now Ford has developed unique rim nuts that can make wheels more secure using 3D printing technology.

Together with EOS, a leading supplier for high-end solutions in 3D additive manufacturing, Ford has created locking nuts with contours based on the driver’s voice. Like an iris scan or a fingerprint, a person’s voice can be used as a unique biometric identification.

Engineers record the driver’s voice for a minimum of one second, saying something like ‘I drive a Ford Mustang’, and use software to convert that singular soundwave into a physical, printable pattern. This pattern is then turned into a circle and used as the design for the locking nut’s indentation and key.

Ford Develops 3D-Printed Locking Wheel Nuts

With the geometry in place, the nut and key are designed as one piece, then 3D-printed using acid and corrosion resistant stainless steel. When finished, the nut and key are separated, with a small amount of grinding required to make them ready for use.

Additional security features
The design also includes second-level security features that prevent the nut from being cloned or copied. The unevenly spaced ribs inside the nut and indentations that widen the deeper they go prevent a thief from making a wax imprint of the pattern, as the wax breaks when it is pulled from the nut.

If not using the driver’s voice to create the contours, the nuts could feature designs specific to a vehicle, such as with the Mustang logo, or use the driver’s initials. The design could also take inspiration from a driver’s interest, for example, by using the outline of a famous racetrack.

Expanding use of 3D printing
3D printing, or additive manufacturing, offers design flexibility to help reduce weight, improve performance and create parts that wouldn’t be possible using conventional methods. For more than 30 years, Ford has increasingly used 3D printing to make prototype parts which help reduce the development time for new vehicles.

Ford Develops 3D-Printed Locking Wheel Nuts

The company has also used this technology to create parts that feature in the Ford GT, Focus and Mustang GT500, and will make more 3D-printed parts in the future. Special bespoke car parts are also 3D printed, including the intake manifold in Ken Block’s Hoonitruck and the pair of wind louvres found on the M-Sport Ford Fiesta World Rally Championship car.

On the Ford production line, 3D printing is used to create assembly line tools that are up to 50% lighter, which makes repetitive tasks less physically stressful and helps improve manufacturing quality. As many of these tools are made of nylon, Ford has introduced a recycling programme that turns old 3D-printed pieces and plastics from manufacturing areas into 100% recycled nylon.

Ford Develops 3D-Printed Locking Wheel Nuts

Ford also creates 3D-printed safety equipment, such as protection sleeves for rotating tools used on the production line, which prevent operators from incurring finger and arm injuries.

“Having our very own plug-and-play printer enables us to make tools and parts exactly when we need them, and to replace them faster than ever before. For some tools, the delivery time was up to 8 weeks but with 3D printing, the turn-around has been reduced to just five days. Best of all, anyone can sit down, create the part they need and start printing it using recycled plastic,” said Lars Bognar, a research engineer for Advanced Materials and Processes at Ford of Europe.

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Hypercars are the supercars of the 21st century and breaking away from the traditional big internal combustion engines of the 20th century, they are propelled by electric motors or hybrid powertrains. And where it was only car manufacturers that had the resources to develop powerful cars, the availability of modern technologies like 3D printing has made it possible for anyone with enough money to start a small company to develop and make a few.

Kevin Czinger (pronounced ‘zinger’) is one such entrepreneur who has developed and built a hypercar with proprietary hybrid powertrain and additively manufactured chassis that is claimed to be an evolutionary leap in performance vehicle creation.

2020 Czinger 21C

2020 Czinger 21C

Though he went to law school, Czinger has been involved in advanced car development for more than 10 years, employing advanced production technologies. The Czinger 21C hypercar is designed, manufactured and assembled at his base in Los Angeles, California. It incorporates vehicle architecture that is centered around driver-focused, 2-person in-line seating configuration within what would almost certainly be a carbonfibre shell.

Details of the powertrain are not revealed at this time, but it is said to have been tested and generated 1,233 bhp. This can get the 21C from standstill to 100 km/h in 1.9 seconds, it is claimed.

The brand launch and 21C’s debut will be at the Geneva International Motor Show next month. In the meantime, Czinger has released two videos which show the car moving very fast across a naval base in San Francisco and on the Pacific Coast Highway in California.

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At first glance, it looks like a normal mirror, but it isn’t. It is a 3D-printed part, a technology that CUPRA has begun to implement in the development of the new Leon Competition racing car in collaboration with HP. Greater agility, efficiency and flexibility are the benefits of a system that is set to revolutionise car development.

2020 CUPRA Leon Competition

2020 CUPRA Leon Competition

“For the new CUPRA Leon Competition, we modelled the steering wheel’s centre control module, the bonnet air vents, door mirrors and the brake and water-cooling inlets,” explained Xavi Serra, the Head of technical development at CUPRA Racing. “These parts were produced using HP’s industrial-grade Jet Fusion 5200 3D printing solution and included in the demanding development tests put to the new racing model.”

More efficiency, greater speed
The main goal with this technology, which offers multiple benefits, is to have a lot of parts in a short time. Engineers can quickly test a wide variety of designs and furthermore, since vehicle development is now done in parallel, this technology enables quicker response to any changes in the design process.

“The work with CUPRA demonstrates the power of 3D printing and digital manufacturing – changing the way the world designs and manufactures,” said Virginia Palacios, Head of Systems Product Management, 3D Printing & Digital Manufacturing, HP Inc.

Wind-tested 3D parts
In TCR competition, the door mirror is a part which, according to the rules, must have the same shape as the production car. But the CUPRA engineers went one step further. “We wanted to add an additional function, which is to cool the driver. We therefore had to design an air intake in the maximum pressure zone to achieve this effect,” said Xavi.

The place where these materials are tested is the wind tunnel, where the 3D-printed parts are verified in exactly the same way as the rest. “The bigger the variety of parts we can test in this facility, the better. It enables us to make much faster progress,” he added.

2020 CUPRA Competition
The new Leon Competition with its 3D printed parts was tested to the limit on the Portimao track in Portugal.

2020 CUPRA Competition

As it is a racing car, the final phase of development can only be carried out in one place: the circuit. “The results were excellent, and some were even surprising, because we were looking to push the material to its limits,” the CUPRA engineer reported.

Making complex ideas a reality – fast
“3D printing is going to signal a turning point in the automotive industry by accelerating lead times and HP 3D technology is helping designers create parts that could not be produced with other technologies,” said Palacios, predicting that the technology will continue to be key in countless fields to make the most complex ideas a reality.

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