Uniformity Labs highlights benefits of its AlSi10Mg powder and build parameters in engine component design

September 8, 2022

A CAD image of cam tray as a consolidated component is shown left, compared to the original design shown during engine assembly (Courtesy Uniformity Labs/Polimotor)
A CAD image of cam tray as a consolidated component is shown left, compared to the original design shown during engine assembly (Courtesy Uniformity Labs/Polimotor)

Uniformity Labs, Fremont, California, USA, has partnered with race car engine developer Polimotor, Wellington, Florida, and Incodema3D, Freeville, New York, to additively manufacture and evaluate a cam tray component for use in an engine designed by Polimotor.

Incodema3D used an EOS M290 Additive Manufacturing machine to build the cam trays. The first step was to simulate and compare build times using conventional EOS M290 AlSi10Mg powder and parameters versus Uniformity AlSi10Mg powder and Uniformity optimised parameters.

Uniformity executed build time simulations using Uniformity HPS settings at 30 μm and 50 μm to compare with EOS 30 μm and 40 μm standard settings. Incodema3D then additively manufactured two halves of the cam tray at 30 μm and 50 μm layers to validate the simulated build times.

The results showed that the actual build times were within 1% of those simulated, illustrating the accuracy of the simulations and the ability to use them as a quoting tool.

It was reported that Uniformity as-built densities were 99.9%, compared to EOS ≥99.8%. Uniformity mechanical properties at 30 μm were said to be superior to best-in-class 30 μm, and at 50 μm are comparable to best-in-class 40 μm. Uniformity also achieved less than 4 μm Ra on as-built vertical surfaces at 30 um layer thickness, with slightly higher values at 50 μm layer thickness.

It was added that at the same 30 um layers, Incodema3D demonstrated a 181% improvement in throughput versus EOS conventional powder and parameters with no compromise to material properties. At 50 um layers, Incodema3D demonstrated a 163% improvement in throughput versus EOS conventional 40 um build time without compromise to material properties, delivering an average density of 99.85%.

“This is a strategically important case study because it shows the significant advantages of using our engineered materials for advanced manufacturing of critical components for use in the transportation industry,” stated Uniformity founder and CEO Adam Hopkins. “The results show that we can achieve faster, more cost-effective part production without compromising material properties.”

Matti Holtzberg, founder, Polimotor, added, “Since we created the world’s first super light-weight polymer engine in 1980, manufacturing technologies have advanced to allow us to include 3D printed metal components along with the polymer components in the engine design. The case study we just completed on the engine cam tray, with Uniformity’s advanced aluminium alloy powder and print parameters, produced at Incodema3D, shows substantial benefits in manufacturing time, which will have a significant impact on reducing the cost to make these and other components for our engine.”

“Along with the inherent benefits 3D printing provides in reducing weight and optimising designs, the ability to reduce cost without compromise to material properties has significant implications not just for producing racing engines but for the global auto industry, which faces a growing demand for lighter, more fuel-efficient cars,” Holtzberg concluded.

The full case study is available here.




In the latest issue of Metal AM magazine

Download PDF

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online
Share via
Copy link
Powered by Social Snap