15 Nov 2016

Sinterline® technology combined with MMI Technyl® Design shape the future of 3D printed functional automotive parts

For the first time, Solvay applied its predictive simulation solution MMI Technyl® Design* to a functional 3D printed automotive part in Sinterline® – the plenum chamber for the breakthrough Polimotor 2 all-plastic engine project. Polimotor 2 aims to develop an engine weighing 63 to 67 kgs (138-148lbs), about 40 kgs (90lbs) less than today’s standard production engine, thereby lowering fuel consumption and CO2 emissions.

“The plenum fabricated with Sinterline® Technyl® PA6 technology could easily perform without failure under real operating conditions,”said Matti Holtzberg, Designer and Leaderof the Polimotor projects.“Integrating the 3D printed part with predictive simulation demonstrated all the additional benefits we could obtain to further reduce weight.”

Coupled with a deep understanding of the parameters of Sinterline® materials and SLS printing processes, the predictive performance simulations showed the plenum’s original design could be up to 30 percent lighter than originally thought possible.

“The successful validation of part performance modeling for PA6 3D printing will help boost the technology and change the traditional landscape of manufacturing,”adds Dominique Giannotta, Sinterline® Program Leader for Solvay. “Enthusiastic feedback from major automotive industry players confirms their interest to accelerate this development in order to offer them a combined service in the near future.”

*MMI Technyl® Design is an advanced service powered by Digimat™ from e-Xstream, an MSC Software company.