Unrestrained Design and Premium-Quality Production for Automotive Accessories

Success Story Automotive

Source: EOS, Spartacus 3D Challenge Manufacture high-quality accessories for DS 3 limited edition cars with unique designs and swift time-to-market

Solution Series production of the parts on an EOS M 290 in EOS Titanium Ti64

Results Cost-efficient: production of 200 parts per build job without impact on quality Fast: less than 1 hour production time per part Precise: process parameter improvements to avoid distortion Additively manufactured of the 30 cm long and thin door titanium component for handle cover while building upright DS3 Dark Side limited edition Freedom of design: three- cars: inside door handle dimensional intricate titanium covers with a very intricate mesh meet requirements of titanium mesh on the upper DS Automobiles for innovation side and premium exclusivity Spartacus3D, a subsidiary of the was a good candidate for maximum ments of the DS design team. The DS 3 Dark Side Limited Edition – French material transformation distortion. Adding a stress-reliev- parametric design fully leverages group Farinia, met all these require- ing heat treatment was not viable the potential of EOS technology: the Advanced Innovation ments: having used 3D printing for costwise; instead, some specific very complex original design of the years, the company has very deep parameters were used to prevent two parts could be produced almost Through Additive Manufacturing knowledge of additive manufac- this risk. Other ways of shrinking one to one thanks to additive manu- turing to help them translate the the cost include increasing the parts facturing and was optimized, so that designs provided by the DS team per batch or reducing the number multiple units could be manufac- into production. With their EOS of supports, the powder consump- In the automotive sector, limited editions of successful models are tured at the same time. This reduced M 290 machine and EOS Titanium tion, the post-processing time, etc. the production costs to a minimum. a smart marketing move. But car makers are always looking for Short Profile Ti64, Spartacus3D possessed all the specific ways to distinguish themselves from their competitors within Spartacus3D is an industrial skills needed to meet the design The AM expertise of Spartacus3D The material, EOS Titanium Ti64, their market segments. DS Automobiles, a brand by the PSA Group, expert in additive manufactur- and quality requirements that was invaluable throughout every also allowed for post-production managed to establish itself on the premium segment within a few ing that supports companies DS Automobiles was striving toward, step of the process, from design finishing, giving a shiny surface years thanks to a series of iconic models. The compact DS 3 model in their transition to metal as well as the production and engineering to 3D printing optimi- and a premium look to the door has received widespread recognition throughout this segment, with additive manufacturing and post-treatment capacities required zation, resulting in shorter product handle covers and key holder. The limited edition models being unveiled on a regular basis. For the Dark ensures that the potential of to deliver the project on time. development life cycles and quicker results could almost be described Side edition, DS Automobile wanted to go further than the usual this technology is maximized time-to-market. Selecting the as art with a sleek, refined design equipment by including 3D printed parts to highlight their continu- for their customers’ appli- Solution optimal material helped to ensure and a very intricate structure that ous dedication to innovation. Additive manufacturing gave complete cations. It is a subsidiary of rigidity and guarantee maximum perfectly combines French elegance, creative freedom to the DS design team, as well as very fast and easy Farinia Group, a manufactur- The DS design team used an inno- part quality after post-processing. innovation and premium exclusivity ing organization dedicated vative parametric design to create implementation and production thanks to Spartacus3D experts work- - everything that DS Automobiles to material transformation, the inside door handle covers and “Being selected to partner with stands for. ing with an EOS M 290 machine. which employs more than the electronic key holder detail in a DS Automobiles on this very innova- 1,700 people in 12 plants in very intricate titanium mesh, high- tive project is a privilege. Their brand There were about 10 production runs France and has mastered lighting the innovation and quality has faithfully represented elegance for a total of 2,000 pieces - 3 items Challenge 4 different technologies: dedication of DS Automobiles. and know-how in the French in each car – taking roughly 2,000 forging, casting, machining automotive industry for years. This hours of manufacturing. The whole The project started when the expertise and enough production and additive manufacturing. In order to find the best compromise also means that our efforts are project was completed in just a few DS Design team began looking for capacity to accommodate their between quality, cost and design, being rewarded and shows that weeks from the validation of the innovative enhancements to the volume requirements. The objective Further information many iterations were necessary Spartacus3D is capable of offering design by the DS design team to the interior of the DS 3 limited edition. was to deliver around 700 cars onto www.farinia.com between the DS design team and robust solutions for serial produc- delivery of the final parts. The accessories needed to highlight the markets worldwide. The project www.spartacus3d.com Spartacus3D. This included the tion. Using the DMLS systems that the car maker’s constant search also had a limited development manufacturing of several prototypes, we have in our workshop, we knew DS Automobiles was able to create for innovation and while satisfying time frame to match the production something that additive manufac- we would be able to produce the something unique in the automotive the highest standards of quality planning of the car, with very precise turing makes particularly easy to best parts,” says Charles de Forges, sector by going beyond the limits of demanded by the premium seg- targets in terms of go-to-market. perform in a single production batch. Managing Director of Spartacus3D. traditional manufacturing, allowing ment. From the very beginning, the As part of this process, the the DS 3 Dark Side to stand out from designers decided to leverage the Each limited edition has a specific DS design team also selected the Results its competition. The DS design team potential of additive manufacturing price target, so all additively manu- finish of the parts; they ultimate- was able to manage a complex pro- to present a world premiere in this factured parts must fit into the over- ly settled on an attractive matte Thanks to the 3D printing expertise ject in a very short time thanks to the field. Additive manufacturing opens all budget. The investigation phase finish obtained by manual polishing. of Spartacus3D, it was possible to expertise provided by Spartacus3D up brand new design possibilities; resulted in the choice of two parts: The quality team defined precise develop an additive manufacturing and the capabilities of EOS additive DS Automobiles presents several the door handle and the key holder. acceptance criteria for the distor- strategy optimized for the require- manufacturing solutions. limited editions for the DS 3 every tion, surface quality (e.g. porosity year, so having these new options and shine), and cutting edges. is a real game changer for the team. The design team also chose In parallel to this back-and-forth, “It’s been a tremendous project from start to titanium, a material which gives a Spartacus3D also worked on luxury touch, is resistant and enables optimizing the production of the finish, as exciting as it was challenging for our an easy and good-looking finish. parts; in order to reduce the costs, expertise. We are excited to imagine that all Spartacus3D not only needed to But while 3D printing is commonly determine the best orientation and these cars are now all over the world. And used in the automotive sectors support structure, but also needed throughout all of this project, we knew we could for prototyping, serial production Cost-efficient and reliable: to refine their proprietary laser with AM is still very rare, especial- The EOS M 290 enables the melting strategy. Titanium is known count on reliability, quality and support from EOS.” ly for metal parts. Therefore, DS production of 200 parts per build to generate some residual stresses Automobiles had to find a partner job without impact on quality. during the melting process, and the with both additive manufacturing (Source: Spartacus3D) long and thin door handle cover Charles de Forges, Managing Director, Spartacus3D Headquarters

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