Renault Trucks: Metal Additive Manufacturing could reduce engine weight by 25%

January 13, 2017

Renault Trucks: Metal AM could reduce engine weight by 25%

A team of Renault Trucks engineers and designers is looking to metal Additive Manufacturing to boost the performance of its engines. The Renault Trucks Lyon Powertrain Engineering department has focused on using the technology as a future engine manufacturing process, resulting in a prototype DTI 5 4- cylinder Euro-6 step C engine being designed exclusively using AM.

Renault has reported that rocker arms and camshaft bearing caps were manufactured by metal AM and successfully bench-tested for 600 hours inside a Euro-6 engine.

Renault Trucks: Metal AM could reduce engine weight by 25%

The original rocker arm in a Renault Trucks Euro 6 DTI5 engine


Renault Trucks: Metal AM could reduce engine weight by 25%

The re-designed metal AM version of the rocker arm is shown during a bench test inside a Euro 6 engine

“The aim of this project is to demonstrate the positive impact of metal Additive Manufacturing on the size and weight of an engine. This process has enabled us to reduce the weight of a 4-cylinder engine by 120 kg or 25%,” stated Damien Lemasson, project manager at Renault Trucks. “The tests we have carried out prove the durability of engine components made using 3D printing. It’s not just cosmetic.”

Metal Additive Manufacturing is opening up new opportunities for engine manufacturers. The process allows engineers to optimise the size of parts, reducing the number of assembly operations and therefore the number of components in an engine. In the short-term, this manufacturing procedure can be used for highly specific applications or small runs.

“Additive Manufacturing releases us from constraints and unlocks the creativity of engineers,” added Lemasson. “This procedure is a source of disruptive technology for the engines of tomorrow, which will be lighter and more functional, thereby offering optimal performance.”

The number of components in the DTI 5 engine has been reduced by 25%, making a total of 200 fewer parts. Following on from these successful initial tests, engineers at Renault Trucks will be continuing their work on this manufacturing process to further increase the performance and functionality of truck components

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 184-page issue includes articles and reports on:

  • Cheaper powders, faster build speeds and no thermal stresses? How AM is going supersonic at SPEE3D
  • Current perspectives on metal AM: Hype, volume manufacturing and the geographies of production
  • AM Ventures: An insider’s perspective on venture capital for start-ups in Additive Manufacturing
  • Binder Jetting and beyond: Optimising the use of metal powders for Additive Manufacturing
  • From lightweighting and material efficiency to energy consumption: Where are we on AM’s sustainability journey?
  • AM’s industrial impact celebrated as Sweden hosts ASMET’s fourth Metal Additive Manufacturing Conference
  • Euro PM2019: Effects of humidity and storage conditions on Additive Manufacturing powder quality
  • > More information

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