After the real hit it had with the launch of the NXG XII 600, SLM Solutions unveils today the first part 3D printed on its 12-Laser Machine: an E-Drive housing from Porsche.
This first application aims to demonstrate the differences the new industrial system can make in terms of productivity, size, reliability and safety.
As a reminder, the SLM® technology-based machine uses high-powered lasers to melt metal powder along pre-defined pathways. With twelve overlapping 1 kW lasers and a build envelope of 600x600x600 mm, the NXG XII 600 can produce large-volume square parts with up to 120 µm layer thickness and even more. Thanks to variable beam spot, bi-directional recoating, laser balance and an optimized gas flow can easily improve productivity during manufacturing.
The team at Porsche advanced powertrain engineering department has been able to test these new capabilities. Acknowledged for the large powertrain applications (cylinder blocks, cylinder heads, etc.) they achieve, they designed and 3D printed a complete E-drive housing.
SLM Solutions explains in a press communication that a permanent magnet motor with 800 volt operating voltage delivers up to 205 kW (280 hp). The downstream two-stage transmission is integrated in the same housing and drives the wheels with up to 2,100 Newton meters of torque. This highly integrated approach is designed for use on the front axle of a sports car.
Falk Heilfort, powertrain development engineer of Porsche states: “This new manufacturing technology is technically and economically interesting for us. Possible use cases are especially prototypes in the development phase, special and small series production as well as for motor sport and classic spare parts.”
The manufacturing process required topology optimization with lattice structures to reduce the weight, functional integration of cooling channels, higher stiffness and reduced assembly time by the integration of parts.
The E-drive unit measures 590 x 560 x 367 mm and was built in only 21 hours on the NXG XII 600.
Ralf Frohwerk, Global Head of Business Development of SLM Solutions, is delighted with the excellent results of the Porsche part: “We are glad and proud to cooperate with highly innovate companies like Porsche. The NXG XII 600 achieves unmatched levels of performance and functional improvements of key automotive parts while delivering cost productivity that enables broad use of additive manufacturing technology for true series production. We are thrilled to take this big step towards full industrialization of metal additive manufacturing for Porsche applications.”
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