通过 3D 打印彻底改变摩托车设计：Light Rider 案例研究
技术
- 传感器 - 光学传感器
适用行业
- 航天
- 汽车
适用功能
- 采购
- 产品研发
用例
- 添加剂制造
- 虚拟原型与产品测试
服务
- 系统集成
关于客户
本案例中的客户是APWorks，它是空中客车公司100% 的子公司。 APWorks 成立于 2013 年，在慕尼黑设有生产工厂，致力于探索先进制造技术并为空中客车集团开展创新项目。该公司独立运营，提供设计、材料和 3D 打印方面的专业知识。 APWorks 致力于探索 ALM 的潜力，而 Light Rider 项目是一项内部举措，旨在展示专为 ALM 设计的零件的可能性。该公司还参与了其他项目，包括仿生飞机机舱隔板以及开发第一个用于机器人和汽车应用的全 3D 打印液-液热交换器。
挑战
空中客车公司是最大的飞机制造商之一，一直热衷于减轻重量，因为它直接影响燃油消耗、成本和碳排放。为了进一步探索先进制造技术，空客于2013年成立了专门从事设计、材料和3D打印的子公司APWorks。然而，由于客户项目的机密性，APWorks 发现很难切实展示专为增材层制造 (ALM) 设计的零件的可能性。他们需要一个能够展示 ALM 潜力的项目，并决定制造一辆电动摩托车。我们面临的挑战是设计和生产一款比传统车型轻得多的摩托车，同时保持强度和耐用性。
解决方案
APWorks 使用其专有材料 Scalmalloy（一种专为 ALM 技术开发的铝合金）来构建摩托车的车架。工程师在开发过程的概念阶段使用了 Altair 的一款名为 OptiStruct 的仿真工具，采用了一种称为拓扑优化的方法。这使他们能够在给定的设计空间内针对给定的一组载荷和边界条件优化材料布局，以实现所需的性能目标。工程师还创建了一个中空框架，以进一步减轻质量并提供隐藏电缆和管道的方法。该框架被分为 14 个独立的打印部分，每个部分都设计能承受所有负载。打印完所有部件后，将它们通过 TIG（钨极惰性气体保护焊）焊接在一起。最终产品名为 Light Rider，重量仅为 35 公斤，框架仅重 6 公斤。
运营影响
数量效益
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