Turbo Charger Prototypes in Rapid Manufacturing

The roads are full of drivers who dream of driving a fast car, yet one which is also environmentally friendly. Modern internal-combustion engines make this dream come true. They form the key to increasing power while reducing petrol consumption and thus carbon emissions at the same time. Whereas turbo-charged diesel engines make up the standard these days, Otto engines equipped with turbo chargers are experiencing a renaissance.

The objective here is to build smaller engines with a smaller displacement, but equipped with an additional turbo charger. This allows them to deliver the same power as naturally aspirated engines that have more cubic capacity. This increase in power partially results from multi-stage turbo charging using energy from the exhaust.

In order to function at maximum efficiency, the turbo charger has to retain a perfect geometry. Using construction and simulation tools, developers are capable of designing this geometry with relative precision. However, the final process always involves testing and perfecting the results on the actual part. To do this, near-standard prototypes moulded in the standard material are required.

Purpose: small series - steel castings  

Challenge: Combination of two components

Solution: Assembly layer by layer in the PMMA-service with a subsequent cast via lost wax method.

Technical data

Total size 258 x 193 x 160 mm
Weight 0.5 kg
Individual pieces1
Material PMMA
Layer thickness 0.15 mm
Lead time 5 days
Build time9 hours