EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 1 EDAG INSIGHTS 1/15 EDAG LIGHT COCOON PROGRESSIVE AUTOMOBILE DESIGN AND BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES AND ADDITIVE MANUFACTURING PROCESSES EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 2 EDAG LIGHT COCOON PROGRESSIVE AUTOMOBILE DESIGN AND BODY DEVELOPMENT USING BIONIC CONSTRUCTION PRINCIPLES AND ADDITIVE MANUFACTURING PROCESSES Inspired by nature. Additively manufactured. And the ultimate in lightweight design. The ”EDAG Light Cocoon“ is a visionary approach towards a compact, dynamic sports car, with a fully bionically optimised, additively manufactured vehicle structure combined with a weatherproof textile outer skin. EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 3 EDAG INSIGHTS CONTENTS 4 The 3D print revolution has begun 5 Technology roadmap of additive manufacturing 7 EDAG Genesis was only the first stept 9 EDAG Light Cocoon: The statement for future lightweight construction 13 Social relevance and sustainibility 14 The concept in details: Drive concept and package Fugenlos beweglich: The Light Cocoon‘s spoiler Personalisation via accounts 20 Conclusion 21 Editorial EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 4 THE 3D PRINT REVOLUTION HAS BEGUN. Everyone is talking about „3D printing“. After consumer printers have flooded the market, industrial applications will follow. Generative manufacturing processes or additive manufacturing will leave the prototype status behind and add a new dimension to the classical manufacturing methods. Additive Manufacturing has long been in use in the automotive and aerospace industries and in medical technology. Above all, small parts and Prototypes can be produced quickly, and without the use of tools. Despite the large number of conceivable position to be able to adopt and copy nature‘s processes on the market, the general principle is construction principles. Developed functionally the same: the material is built up layer by layer, and evolutionarily into optimised structures from without the use of tools, and only a 3D data which man can learn. And the entire process is model of the product must be available as input tool-free, resource-saving and economical. data. This method opens up enormous freedoms Processes such as the thermoplastic-based FDM in development and design which were not pre- process offer the chance of integrating fibre viously possible, due to restrictions in production elements, to represent structural parts. As a imposed by the classical primary forming, re- result, completely new concepts for ultimate shaping and machining manufacturing processes. lightweight design in automobile development Additive manufacturing processes put us in a are already emerging. EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 5 TECHNOLOGY ROADMAP OF ADDITIVE MANUFACTURING Particularly promising additive manufacturing processes have been identified and their technological effects examined as part of an intensive technology analysis carried out by EDAG experts and leading authorities in the field of additive manufacturing. During this think tank, it very quickly became clear that additive manufacturing processes offer considerably more potential than current restrictions in the field of rapid prototyping. SLM – Selective Laser Melting FDM – Fuse Disposition Modeling The principle of this process is similar to This process works on a principle similar to electron beam melting, in which finely that of a hot-melt glue gun: using a nozzle powdered metallic materials are selectively that moves three-dimensionally in an open melted by applying a laser beam in an inert space, melted thermoplastic polymers are gas atmosphere. The mechanical properties sprayed on layer by layer, and built up to correspond by and large to those of the basic produce a workpiece. The introduction of materials. Particle sizes are selected subject to reinforcing fibres, e.g. in the form of attached layer thickness and surface quality. continuous filaments, produces material The installation space for the parts that can properties suitable for structurally relevant be produced is limited. components. The process is still undergoing development. Further advantages of the process are the component dimensions that can be produced (range of the robot arm / additional mobile workpiece) and the possibility of being able to use bio-polymeric materials instead of petroleum-based or biologically degradable polymers. This would supply additional potential for sustainable production. The following diagram shows an assessment of the processes in the form of a technology roadmap up to 2045. Different technological leaps (so-called booster potential) were recorded and analysed, to assess the extent to which they might contribute to the generation of larger vehicle parts. Overall, metal-based SLM and thermoplastic-based FDM looked to be particularly interesting and promising. For details of the technology roadmap and the other processes, see edition 1/14 of EDAG Insights EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 6 THE EDAG ROADMAP: THE EVOLUTION OF ADDITIVE MANUFACTURING IN THE COURSE OF THE NEXT DECADES 2015 2025 2035 2045 ROADMAP ADDITIVE Manufacturing FDM SLA FUSE DEPOSITION MODELING STEREO LITHOGRAPHY Booster potential FDM Principle: melted thermoplastic Prinziple: selective polymerisation Booster potential FDM polymers are sprayed on and built up of fluids by laser (epoxy resins). COMPONENT SIZE Aligned endless fibres with high band width Reactive chemistry layer by layer, using a nozzle that A classic rapid prototyping process moves three-dimensionally in an ECOLOGICAL PERFORMANCE Plasticised material feed since the 1990s. open space. Robotics As a rule. material properties are STRUCTURAL relevance The inclusion of reinforcing fibres geared to model building materials. is still currently being researched Material RANGE (3D fibre printer). PROCESS SPEED TOLERANCE COMPLEXITY Booster potential SLM PRODUCTION COSTS Customised alloys SLM SLS PRECISION Multi-beam/scanner SELECTIVE LASER MELTING SELECTIVE LASER SINTERING Batch SIZE Weight – moulding flask Principle: electron beam melting: Principle: powdered thermoplastic Powdered metallic materials are materials are laser sintered layer by layer Booster potential SLM locally laser remelted under inert gas. in an inert gas atmosphere. Booster potential 3DP Integration of semi-finished products Portal instead of a chamber By and large, mechanical properties Mechanical properties are below those Subsequent treatment processes conform with the basic materials. of injection moulding. Optimisation of system of bonding Particle sizes are selected subject to Booster potential SLM agents for solid materials layer thickness and surface quality. In situ bonding agents Alloy developments Portal instead of printer Scale-up Booster potential FDM Biopolymers 3DP Booster potential FDM Optimisation of fibre matrix 3D PRINTING High performance thermoplastics Multi-jet Booster potential 3DP Principle: solid materials are bound together Catalytic subsequent treatment layer by layer, using suitable bonding agents. Subsequent treatment is carried out to Booster potential SLS define the properties of the workpiece. Booster potential SLS Fibre reinforcement Simultaneous printing of plastics in Optimisation of matrix materials various degrees of hardness and colours. Booster potential SLS Multi-beam/scanner Booster potential SLA Scale-up Integration of fibres in 2D Booster potential 3DP Consumer hype EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 7 ”EDAG GENESIS“ WAS ONLY THE FIRST STEP With „EDAG Genesis“, our exhibit at the 2014 a sandwich component, with fine, inlying bone Geneva Show, we provided a visionary outlook structures that give the shell its strength and for what might well be the next industrial revolu- stability. This concept is reflected in the exhibit. tion in automotive development and production. The „EDAG GENESIS“ can be seen as a symbol The skeleton can be seen as a metaphor; in this of the new freedoms and challenges in design, case, it does not form part of a musculoskeletal development and production that additive ma- system, but instead provides extra passenger nufacturing processes will open up to designers safety. The framework calls to mind a naturally and engineers. The structure is based on the developed skeletal frame, the form and structure bionic patterns of a turtle, which has a shell that of which should make one thing perfectly clear: provides protection and cushioning and is part these organic structures cannot be produced of the animal‘s skeleton. The shell is similar to using conventional tools! EDAG INSIGHTS 1/15 - EDAG LIGHT COCOON 8 Although the turtle had millions of years to production situation, which was unconceivable develop to suit its needs and, for instance, perfect in the past. Additive manufacturing enables its „passenger safety system“, man is still theo- parts to be designed so that they are load- retically at the very beginning of a possible para- specific, multi-functional and bionic, while digm shift. The traditional rules of design, with ensuring ideal (or „topologically optimised“) wall restrictions caused by production, will play only thickness and outstanding material properties. a very minor role in additive manufacturing, and Working directly from the data models, tool-free, the tried and tested construction methods of highly flexible production is possible. nature can also be applied in a genuine series In 2014, the world‘s trade and economic press picked up on the EDAG Genesis and made it a subject of discussion.