Revolutionizing Automotive Design: A Case Study on Technische Universität Dresden's Formula Student Team
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Equipment & Machinery
- Life Sciences
Applicable Functions
- Product Research & Development
Use Cases
- Additive Manufacturing
- Manufacturing Process Simulation
About The Customer
The customer in this case is the Technische Universität Dresden's Formula Student Team, which is involved in designing and manufacturing parts for Formula Student vehicles. The team is composed of students and researchers, including Michael Süß, a Research Fellow at the university who is currently working on his PhD focusing on design guidelines for additive manufacturing/electron beam melting. Michael also works closely with the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, one of Europe's leading research institutions in the fields of adhesive technology, material sciences, and manufacturing techniques. Lucas Hofman, a current student at the university, also collaborated on this project.
The Challenge
The Technische Universität Dresden's Formula Student Team faced the challenge of designing and manufacturing a new Formula Student steering column mount. The existing steering column mount was complex, consisting of four different areas at different angles, making it difficult to produce with a 5-axis milling machine. The solution to produce this part consisted of four different milled aluminum parts that were all bolted together. The team was looking for a way to simplify the design and production process, reduce the weight of the part, and improve its performance characteristics.
The Solution
The team decided to use solidThinking Inspire for the design process and electron beam melting for the production of the new part. SolidThinking Inspire was chosen for its ease of use, integrated analysis tools, and PolyNURBS features, which allowed the team to quickly take optimization results and reconstruct the part for manufacturing. The electron beam melting process was chosen for its freedom in design and fewer design constraints compared to other manufacturing methods. The team worked with the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM to complete the manufacturing using an Arcam A2X electron beam melting machine. The part was produced with a titanium alloy, which contributed to significant weight savings.
Operational Impact
Quantitative Benefit
Case Study missing?
Start adding your own!
Register with your work email and create a new case study profile for your business.
Related Case Studies.
Case Study
Smart Water Filtration Systems
Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.
Case Study
IoT enabled Fleet Management with MindSphere
In view of growing competition, Gämmerler had a strong need to remain competitive via process optimization, reliability and gentle handling of printed products, even at highest press speeds. In addition, a digitalization initiative also included developing a key differentiation via data-driven services offers.
Case Study
Predictive Maintenance for Industrial Chillers
For global leaders in the industrial chiller manufacturing, reliability of the entire production process is of the utmost importance. Chillers are refrigeration systems that produce ice water to provide cooling for a process or industrial application. One of those leaders sought a way to respond to asset performance issues, even before they occur. The intelligence to guarantee maximum reliability of cooling devices is embedded (pre-alarming). A pre-alarming phase means that the cooling device still works, but symptoms may appear, telling manufacturers that a failure is likely to occur in the near future. Chillers who are not internet connected at that moment, provide little insight in this pre-alarming phase.
Case Study
Premium Appliance Producer Innovates with Internet of Everything
Sub-Zero faced the largest product launch in the company’s history:It wanted to launch 60 new products as scheduled while simultaneously opening a new “greenfield” production facility, yet still adhering to stringent quality requirements and manage issues from new supply-chain partners. A the same time, it wanted to increase staff productivity time and collaboration while reducing travel and costs.
Case Study
Integration of PLC with IoT for Bosch Rexroth
The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.
Case Study
Robot Saves Money and Time for US Custom Molding Company
Injection Technology (Itech) is a custom molder for a variety of clients that require precision plastic parts for such products as electric meter covers, dental appliance cases and spools. With 95 employees operating 23 molding machines in a 30,000 square foot plant, Itech wanted to reduce man hours and increase efficiency.