It seems like everyone is using 3D printing now—and the trend isn’t slowing down. For example, we’ve covered the likes of Chevy and Porsche to Czinger and Bugatti. But Volkswagen is now betting on a new method of this revolution, the binder jetting process.
Traditionally, parts have been made using a laser that binds layer of metallic powder together. As the HP video shows, this process means that the laser can only focus on 1 individual component at a time, which is generally time consuming if you have ever seen a 3D printer printing. The new technique is binder jetting: where a printhead, similar to a regular paper printer, adds an adhesive to a layer of metal powder, solidifying the powder, and then adding another layer of powder. The process then repeats.
VW partnered with HP to create these Metal Jet printers and Siemens has been tasked with creating the additive manufacturing software for said printers. Volkswagen has spent tens of millions on this partnership and even opened a dedicated 3D printing center in Wolfsburg, Germany, in 2018 that currently contains 13 printing units. HP released a video for the Metal Jet years ago, along with some interesting Volkswagen specific videos too.
But what’s the advantage of this? As shown by the videos, the binder jetting process is much faster than the traditional laser and powder method. Secondly, Volkswagen claims these parts are nearly 50% lighter than products made of sheet steel. The largest advantage for manufacturers is likely the lack of retooling. Retooling is when factories have to change tools in order to produce different parts. In this case, a computer program is the only change needed when making a new product, adding to the price and time benefits. Until now, 3D printing of large volumes was not feasible, but the opposite appears to be the case with the new binder jetting method; by 2025, Volkswagen aims to manufacture 100,000 parts per year. The first parts—A pillar components for the oddball T-Roc convertible—have been sent to Volkswagen’s Osnabrück factory, where the T-Roc is built, for certification. The point is that this is the new norm: VW itself has made over 1 million parts in the last 25 years, and the binder jetting process is only breaking barriers. What do you think? Do you believe in the success of 3D printed parts? Lighter, stronger, and cheaper to manufacture parts seem great to us. Let us know!
Additional Info:
- https://www.autoweek.com/news/technology/a36786840/vw-will-use-3d-printers-to-make-metallic-car-parts/
- https://www.autocarpro.in/news-international/volkswagen-to-use-new-3d-printing-process-in-vehicle-production-79415
- https://press.hp.com/us/en/press-releases/2018/hp-launches-worlds-most-advanced-metals-3d-printing-technology.html
- https://www.volkswagen-newsroom.com/en/stories/3d-printing-in-action-4177
- Metal Binder Jetting: https://www.youtube.com/watch?v=HHn7mPx8w6U
