Uniformity Labs produces aluminium AM roll cage for solar powered race car

September 24, 2021

Uniformity Labs additively manufactured a roll cage for a solar-powered race car using its AlSi10Mg aluminium alloy powder (Courtesy Globe News Wire)

Uniformity Labs, Fremont, California, USA, reports that it has successfully designed and additively manufactured a roll cage for use in a solar-powered race car. Built from its ultra-low porosity AlSi10Mg aluminium alloy powder, Uniformity Labs optimised the component for an entrant in the Bridgestone World Solar Challenge, an international event for solar-powered cars driving 3000 kilometres through the Australian outback.

The roll cage was built in-house using an SLM 280 2.0 Laser Beam Powder Bed Fusion (PBF-LB) machine from SLM Solutions. Additive Manufacturing enabled the automotive part to be produced with a 30 um layer thickness, achieving an excellent surface finish with best-in-class mechanical properties. It also delivered the added benefit of a productivity level equal to that of a 60 um layer thickness build.

Uniformity Labs explains that the car engineering team used topological optimisation techniques to design the part to ensure strength while reducing material usage and weight. The cost and material performance were critical factors, so they replaced carbon fibre with an AM part made from Uniformity’s AlSi10Mg powder.

“This is an excellent example of how our innovation can significantly improve part design using our advanced powders and modern AM techniques,” stated Adam Hopkins, founder and CEO of Uniformity Labs. “Our ultra-low porosity AlSi10Mg and print processes allowed the car development team to create a better part quickly, cheaply, and optimised for the necessary weight and safety parameters.”

He added, “It’s easy to see how the processes used, and benefits afforded to the roll-cage production can apply to the creation of complex parts for use in mainstream industries such as aviation, auto, and consumer electronics. That’s what our technology is all about.”


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