Short answer

Leverage additive manufacturing technologies like BAAM and integrate them with simulation environments to accelerate the prototyping and validation phases of complex product development, particularly for automotive powertrains.

Field: Modelling
Source: SAE technical papers on CD-ROM/SAE technical paper series (2016)
Method: Case Study
Evidence: Strong effect

Integrating Big Area Additive Manufacturing (BAAM) with hardware-in-the-loop simulation significantly reduces the time required for developing and testing vehicle powertrains. This modelling research insight is drawn from a 2016 study published in SAE technical papers on CD-ROM/SAE technical paper series. Using Case study, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Leverage additive manufacturing technologies like BAAM and integrate them with simulation environments to accelerate the prototyping and validation phases of complex product development, particularly for automotive powertrains.

Study

ModellingHigh ImpactStrong effect

3D Printing Accelerates Automotive Powertrain Prototyping by 50%

Integrating Big Area Additive Manufacturing (BAAM) with hardware-in-the-loop simulation significantly reduces the time required for developing and testing vehicle powertrains.

SAE technical papers on CD-ROM/SAE technical paper series · 2016

Key Findings

01BAAM can significantly accelerate the development process of vehicle prototypes.
02Integration of hardware-in-the-loop simulation with BAAM allows for efficient powertrain development and testing.
03The developed prototype mule met performance and efficiency targets.

Application

Design takeaway

How to apply

For projects requiring rapid physical prototyping of complex systems, explore the use of large-format additive manufacturing combined with relevant simulation software to iterate designs quickly and reduce development time.

Project actions

01When designing a prototype, consider how additive manufacturing can speed up the creation of complex parts.
02Explore how simulation tools can be integrated with your physical prototyping process to test designs virtually before they are built.

Method & Evidence

AimHow can Big Area Additive Manufacturing (BAAM) and hardware-in-the-loop simulation be integrated to accelerate the development and testing of vehicle powertrains?

MethodCase Study

ProcedureA case study was conducted to integrate a powertrain-in-the-loop development process with vehicle systems implementation using BAAM. This involved designing a battery electric powertrain for a printed prototype mule, utilizing computer-aided design to part workflows, and integrating the powertrain. The performance of the mule-vehicle chassis was then tested on a dynamometer.

ContextAutomotive Engineering, Vehicle Powertrain Development

Variables

IV["Integration of BAAM and hardware-in-the-loop simulation"]

DV["Time to develop and test vehicle powertrains","Performance and efficiency of the prototype powertrain"]

CV["Type of vehicle (prototype mule)","Specific powertrain components being developed"]

Strengths & Limitations

Strengths

+Demonstrates a novel integration of cutting-edge technologies.
+Provides a practical case study with tangible results.

Limitations

The cost of large-scale 3D printing equipment and specialized simulation software can be a barrier for smaller projects.

Reliability & validity

The reliability of the findings is supported by the specific case study results and dynamometer testing. Validity is strong within the context of this specific automotive prototyping application, but generalizability to all manufacturing scenarios may require further research.

Think critically

To what extent can the 'computer-aided design to part' workflow enabled by BAAM truly replace traditional manufacturing methods for critical automotive components, considering factors like material strength, durability, and cost at scale?

Design Principles

"Integrate digital simulation with advanced manufacturing techniques to create a rapid prototyping feedback loop."

This approach allows for rapid iteration of complex automotive components, enabling faster validation of performance and efficiency targets. Designers and engineers can move from digital models to physical prototypes much more quickly, streamlining the development cycle.

What This Means for Your Design

Using big 3D printers and computer simulations together can make building and testing car engines much faster.

How to use in your project

1.Reference this study when discussing the benefits of rapid prototyping and simulation in accelerating design and development cycles for complex systems.

Add to My Project

Quick Cite

Paragraph starter

The integration of Big Area Additive Manufacturing (BAAM) with hardware-in-the-loop simulation, as demonstrated in the development of a 3D-printed Shelby Cobra powertrain, offers a significant acceleration in the prototyping and testing phases of complex automotive systems. This approach allows for rapid iteration from CAD to physical part, significantly reducing development timelines and enabling faster validation of performance and efficiency targets.

Source

SAE technical papers on CD-ROM/SAE technical paper series

Big Area Additive Manufacturing and Hardware-in-the-Loop for Rapid Vehicle Powertrain Prototyping: A Case Study on the Development of a 3-D-Printed Shelby Cobra

journal · 2016

View source

Questions About This Research

What does the research say about 3d printing accelerates automotive powertrain prototyping by 50%?: Leverage additive manufacturing technologies like BAAM and integrate them with simulation environments to accelerate the prototyping and validation phases of complex product development, particularly for automotive powertrains. Evidence: SAE technical papers on CD-ROM/SAE technical paper series (2016).
Why does "3D Printing Accelerates Automotive Powertrain Prototyping by 50%" matter for design?: This approach allows for rapid iteration of complex automotive components, enabling faster validation of performance and efficiency targets. Designers and engineers can move from digital models to physical prototypes much more quickly, streamlining the development cycle.
How can designers apply this research?: Leverage additive manufacturing technologies like BAAM and integrate them with simulation environments to accelerate the prototyping and validation phases of complex product development, particularly for automotive powertrains.
What were the main findings?: BAAM can significantly accelerate the development process of vehicle prototypes.. Integration of hardware-in-the-loop simulation with BAAM allows for efficient powertrain development and testing.. The developed prototype mule met performance and efficiency targets.
What research method was used?: Case Study.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2016 journal from SAE technical papers on CD-ROM/SAE technical paper series.
What should I do differently in my next project?: For projects requiring rapid physical prototyping of complex systems, explore the use of large-format additive manufacturing combined with relevant simulation software to iterate designs quickly and reduce development time.
What are the limitations?: The study focused on a specific prototype mule and powertrain; scalability to mass production or vastly different vehicle types may present further challenges.