Nottingham University
Nottingham Uni car component
A lattice specimen, specifically triply periodic minimal surface (TPMS) lattice structures, which are a focus of the FLAC project. This specimen was designed using software being developed during the project
Engineers at The University of Nottingham are additively manufacturing lightweight automotive components, boosting vehicle fuel efficiency while reducing noise and CO2 emissions.
The components will be constructed using selective laser melting technology. Helping to increase functionality and lower the number of separate components in production, SLM will be useful in the reduction of weight.
These components are being produced as part of the Functional Lattices for Automotive Components (FLAC) project. This project aims to achieve significant weight reductions in mass and optimised thermos-mechanical performance in new vehicle components.
“FLAC will benefit UK automotive companies, increasing their competitiveness by allowing them to adopt innovative routes for the design and manufacture of lightweight on-vehicle componentry, with shorter lead times and lower costs than are presently available,” said Professor Chris Tuck, FLAC project lead from the Additive Manufacturing and 3D Printing Research Group.
The use of advanced lightweight materials in the project will serve to minimise wastage, as well as emit less CO2. Only the required material is incorporated into the built component, reducing costs, and increasing the ability to manipulate the material to achieve the required performance and efficiency.
University of Nottingham
Nottingham Uni car component
Often used for mechanical testing, the researchers will be testing the strength of specimens like this so that they can then design more sophisticated lattice components.
Environmental advantages include the inherent recyclability of the aluminium powder waste, reduced transportation and the elimination of special tooling and hazardous cutting fluids to produce the SLM parts.
FLAC, lasting three years, will demonstrate the viability and cost analysis of the industrialisation of SLM, along with possible manufacturing routes and supply chain models. Having secured £368,286 from Innovate UK, the project will investigate components such as brake calipers, heat sinks for LED headlights and power train sub-systems. The short-term market opportunity for these components – which will also deliver a decrease in CO2 emissions by 16.97g/km – lies in the luxury car and motorsport markets.
“The automotive sector is one of the UK’s leading export sectors by value, representing around 6.3% of all UK exports,” added Professor Tuck. “Successful delivery of FLAC’s portfolio will enhance the research and development leadership in the key automotive technologies, and strengthen the UK automotive supply chain, resulting in increased revenues to the UK economy and government.”
