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Reimagining Piston Design with Additive Manufacturing: A HardMarque Case Study
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Automotive
- Equipment & Machinery
Applicable Functions
- Product Research & Development
Use Cases
- Additive Manufacturing
- Rapid Prototyping
The Challenge
HardMarque, a digital design and manufacturing studio, was faced with the challenge of reimagining the current piston design process. The goal was to manufacture a piston that was not only lighter than the current versions but also equally as strong. This was a significant challenge as it required a balance between weight reduction and strength maintenance, which is a critical factor in the performance and efficiency of automotive engines. The challenge also extended to the integration of the new design with additive manufacturing equipment, a process that required precision and compatibility with the chosen material, titanium.
About The Customer
HardMarque is a digital design and manufacturing studio based in Australia. The company is focused on creating 'Future Factories', additive-manufacturing facilities that concentrate on just-in-time production and delivery of custom, made-to-order parts ordered through the Internet. HardMarque believes that this type of innovation is crucial to the future of manufacturing in Australia, helping the country break into new markets by emerging from the constraints of traditional manufacturing. The company's director, Nicholas Hardman, is a long-time CAD user who has found great value in the use of solidThinking Inspire and Evolve for concept generation and design refinement.
The Solution
HardMarque incorporated a process that utilized both solidThinking Inspire and Evolve for concept development and design refinement. The design process began with an existing piston for benchmarking. The measurements of the piston were used to create an initial design space in Evolve. After the design space was created, the model was exported to Inspire for concept generation. Accurate loading conditions were applied to the piston design, considering forces from expanding combustion gas and lateral force from oil pressure against the cylinder wall. The ideal shape for the piston was generated based on these loading scenarios. The shape was then imported back into Evolve for interpretation into the final piston design, which was manufactured using titanium additive manufacturing.
Operational Impact
Quantitative Benefit
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