Additive technologies are increasingly used in the automotive industry. Porsche has announced that it is using 3D printing to produce lightweight pistons for the engine of its flagship 911 GT2 RS sports car.
3D printing makes it possible to produce pistons with a topologically optimized design (that is, reinforced in the load zone and lighter where there are less loads). As a result, the parts come out 10% lighter than similar serial forged parts. They also received a built-in and closed cooling channel in the piston head, which cannot be made by conventional methods.
“With the new, lighter pistons, we can increase the engine speed, reduce the thermal load on the pistons and optimize combustion. This allows you to get 30 hp. more power from the original 700 hp biturbo engine and at the same time improve efficiency,” says Frank Ickinger from Porsche Advanced Engine Development.
There are a number of different technologies for 3D printing. All of them are based on the principle that the components are "printed" layer by layer without the need to pre-make a special tool or mold. Therefore, almost any geometric shape can be realized. A 3D printer is capable of receiving design data directly from a computer. Thus, additive processes are ideal for producing structures that have been designed and optimized using artificial intelligence (AI).
The pistons for the Porsche 911 GT2 RS are made from metal powder using a laser metal fusion (LMF) process. The laser beam heats and melts the surface of the powder to match the contour of the part.
The 3D printed piston project was initiated by Porsche in collaboration with component manufacturers Mahle and Trumpf. Component quality and performance verified using Zeiss measurement technology.
3D-printed pistons allowed Porsche to increase power by 30 hp.
