Recently updated on September 3, 2021 at 06:21 am
Volkswagen is promoting the use of innovative 3D printers in car production. For the first time, the latest process - so-called binder jetting - has now been used in parts production at the main plant in Wolfsburg. If a component is built up layer by layer from metallic powder with conventional 3D printing by a laser, this is done by an adhesive in the binder jetting process. The resulting component is then heated and shaped into a metallic part. The binder jetting process reduces costs and increases productivity - for example, the parts are only half as heavy as with sheet steel. Volkswagen is currently the only car manufacturer to implement the entire production process for this 3D printing technology. "We are consistently pushing ahead with our future topics - even in the persistently difficult environment of the corona pandemic", says Christian Vollmer, Member of the Board of Management for Production and Logistics at Volkswagen Passenger Cars and make it ready for use in series production. "
3D printing process
Cedrik Neike, Member of the Board of Management of Siemens AG and CEO Digital Industries: “We are very proud to support Volkswagen with our innovative solutions in the 3D printing process. Our automation and software solutions are leaders in industrial production. With this technology, Volkswagen can develop and produce important components even faster, more flexibly and in a way that conserves resources. "
In the past five years, Volkswagen has invested an amount in the mid double-digit million euro range to boost innovation. In addition, the company has entered into a software partnership with Siemens, and the existing cooperation with printer manufacturer HP Inc. has also been expanded. Together with the first complete use of binder jetting, important experience should be gained, for example which components will be manufactured economically and quickly in the future and how additive manufacturing can support the digital transformation of production at Volkswagen.
HP supplies the corresponding high-tech printers and Siemens supplies the special software for additive manufacturing. An important process step - which Siemens and VW have jointly expanded - is the optimization of the positioning of components in the installation space. In so-called “nesting”, up to twice as many parts can be produced per printing process.
The three companies want to set up a joint team of experts around the Wolfsburg 3D printing center from summer onwards. The ultra-modern center started at the end of 2018 and enables the production of complex vehicle parts using 3D printing. The system also serves to qualify employees for the use of these technologies.
Up to 2025 parts per year for Volkswagen are to be produced using 100.000D printing in Wolfsburg by 3. The first components from the binder jetting process are going to be certified in Osnabrück: parts for the A-pillar of the T-Roc convertible. These weigh almost 50 percent less than conventional sheet steel parts. It is precisely these savings that make the process particularly interesting in car production. Volkswagen has already successfully crash-tested 3D-printed metallurgical vehicle components. Production in larger numbers has not yet been economical enough - thanks to the new technology and the closed cooperation, use in series production is, however, economically feasible.
Already a million parts printed in 25 years
Volkswagen has been working with 25D printing for 3 years - and originally started in the field of technical development with the aim of accelerating the development of vehicles and making them more cost-effective. Today, 13 systems are operated at the Wolfsburg location, which can produce both plastic and metal components using different printing processes. Typical examples are plastic components for prototypes such as center consoles, door panels and instrument panels through to bumpers. In metal printing, suction pipes, heat sinks, holders and carrier parts are printed, among other things. In the past 25 years, more than a million components have been manufactured.
The cooperation with Siemens is part of a comprehensive, strategic partnership in the field of digital production platforms that both companies have entered into. Volkswagen Board Member Vollmer: “I am delighted that in Siemens we have found a strong and innovative partner with whom we can start the car production of tomorrow now. The example of 3D printing shows that the transformation offers many different and innovative opportunities. "
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