Additive solutions for motorsports

• Delivery of parts within a few weeks/days
• Order directly on demand
• Test different designs at the same time without additional cost
• Production of exact amount of required parts is possible
• Reduced leadtime and cost
• Fast turn around time
• 1:1 copy of your part (even if not produced anymore)
• Digital warehouse
• No storage or tooling costs
• Reduced risk thanks to in-house post-processes 

• Characterization of material properties
• Support and consulting in the product development process
• Additive manufacturing oriented and compliant designs
• Integration of additional functions and neighbor parts
• Topology optimization and FEM simulation
• Static and dynamic validation of components also under thermal boundary conditions
• Leakage testing
• Metallurgical analysis of components 

• Strong focus on the part functionality
• Better design possibilities even compared to casting
• Extreme shapes:
  ‒ Hollow structures
  ‒ Unique double-wall construction design
  ‒ Very thin walls <1mm
• Very complex shapes from thick to thin in one part
• Topological optimization and possibility to integrate lattice structure: extreme weight and material reduction

• Increased air flow through the cylinders’ combustion chamber augments the engine power output
• Reduced weight of the usually heavy doubled walls - while achieving the thermal insulation required for optimal performance thanks to an air gap (not feasible with traditional casting methods)
• Effective operation of the turbocharger thanks to increased thermal insulation
• Cost advantage: not only within the geometry and performance of the application but cost savings through the reduction of process steps such as machining

Functional integration through product development and process know-how:

• Integrating three single parts into one design
• Reduction of welding to attach double-walled heat shield for joint/assembly activities and process steps e.g. tooling and or machining processes
• Increased overall reliability of the turbocharger due to single-piece production
• Reduced leakage risk at the interface between the different parts

• Density: almost no inner porosities (in additive manufacturing evenly >99.5; in casting strongly influenced by the part geometry)
• Additive manufacturing could avoid HIP-treatment (cost intensive process step)
• Microstructure is finer than with casting: the tensile strength of additive manufacturing material is higher
• High repeatability in additive manufacturing 

• Cost reduction as mating surfaces no longer need to be machined to tight tolerances
• Reduced lead time compared to functional surface creation via casting
• Cost-neutral feature
• Possibility to create closed cavities without the need of molding or post-processing