Industry Trends

• The strong trend towards vehicle electrification is driving the need and urgency for complete solutions for electric drive engineering. Numerous OEMs (both traditional OEMs and start-ups) and governing entities (e.g., France, London, California, China, India, etc.) have clearly indicated their strategic intent to move their states in the direction of vehicle electrification now and into the near future.
• Consumers expect equal or better performance from Battery Electric Vehicles versus Internal Combustion Engine vehicles, with all the added benefits of lower fuel costs and lower emissions.
• OEMs are recognizing the long-term strategic importance of having core competency in battery and electric drive engineering and are increasingly bring this work in-house rather than relying on suppliers.
• Electromagnetic performance is strongly affected by temperature, so thermal management of the electric drive is a key engineering factor, which in turn is requiring OEMs to completely overhaul their vehicle thermal management strategies.
• Consumers expect acceptable levels of noise and vibration in the cabin – this Noise & Vibration engineering challenge is exacerbated by the elimination of the internal combustion engine noise and vibration which has raised consumer awareness to electric motor noise

 

Engineering Objectives

The primary requirement of the electric drive unit is to deliver power in the form of mechanical torque which is directly dependent on its size. However, the size of the electric drive is constrained by form factor (available volume and mass). Hence the engineering objectives for an electric drive are:

 

Achieve market-required high power density while managing cost and supply chain risk: The motor design aims to minimize space while still delivering the highest possible power output. Use of rare-earth materials, which can typically help achieve this goal, are expensive and subject to supply chain risk.

• Optimize performance and efficiency across multiple disciplines: Electromagnetic performance must be balanced against thermal management, strength and durability, and noise and vibration attributes.
• Minimize risk of warranty claims & recalls.
• Manage occupant comfort (acoustic noise): Removal of traditional IC engine noise brings high frequency motor noises to the attention of vehicle occupants. This is a new challenge for automotive engineering.

 

Challenges

Describe the key challenges faced by most customers today in executing this process efficiently and effectively.

Electric Drive Engineering Challenges:

• Extreme packaging constraints
• Design and production cost constraints
• Difficult to predict and optimize complex discipline behaviors as well as the interactions across disciplines (electromagnetic performance, thermal, strength, durability, noise & vibration)
• Disconnected tools, organizations, and processes
• The electric drive is a sub-system of the larger, complex electric powertrain system. Its control system needs to be integrated within the overall vehicle control strategy.
• Maintaining electric machine air gap at high rpm ( as high as 30,000 rpm) and high centrifugal loads (air gap between stator and rotor)
• E-drive durability requires consideration of high rotational speeds and overall levels of vibration.

 

 

With the Electric Drive Engineering industry process, we can

• Optimize electric machine rotor and stator design using electromagnetic simulations to predict torque, flux, induced voltage and power, while minimizing losses and preventing demagnetization
• Perform multi-body dynamics and structural simulations given outputs from electromagnetic analysis to minimize vibration and ensure durable and quiet operation
• Execute thermal analysis to maintain operating temperatures across all performance conditions
• Minimize churning losses between oil and gears, while making sure contact surfaces are properly lubricated

Electric Drive Engineering following important characteristics

• Electric Machine
• Gearbox
• Structural Housing

 

Benefits

Electric Drive Engineering Industry Process Experience Benefits:

• Development time & cost reduced by as much as 1/3
  • Simulation activities tightly integrated with Design (CAD)
  • Integration of multi-disciplinary tools enables more efficient trade-off analysis
  • Ease of use enables democratization of engineering activities across designers and domain experts
• Accurate prediction of multidisciplinary KPIs and opportunity for multidisciplinary design optimization
  • Best in class individual disciplinary tools (electromagnetic performance, thermal management, strength and durability, noise and vibration)
  • Integration of multiple disciplines enabling trade-off studies and multidisciplinary optimization
• True systems engineering approach to minimize complexity and ensure compliance with requirements
  • This Industry Process Experience incorporates Model Based Systems Engineering methodologies and tools on the 3DEXPERIENCE Platform
• Reduced risk of warranty and recall
  • Detailed validation and verification can be performed
• Consumer delight with performance, efficiency and comfort

 

What is Lens DED Technology?

Lens DED (Laser Engineered Net Shaping Directed Energy Deposition) is an advanced additive manufacturing process that uses a high-power laser to melt and deposit metallic powders or wire feedstock layer by layer. This technology enables the creation, repair, and enhancement of components with high precision, offering advantages such as material efficiency, the ability to produce complex geometries, and reduced lead times. It is widely used in industries like aerospace, automotive, and medical for manufacturing custom parts, repairing damaged components, and improving product performance. Lens DED also allows for minimal material waste and customization, though post-processing may be needed to achieve the desired surface finish. 

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Applications of Lens Directed Energy Deposition Technology in Aerospace 

1. Component Repair

Aerospace components, including turbine blades, engine parts, and structural elements, are subjected to extreme conditions that lead to wear and damage over time. Traditional repair methods are often costly and time-consuming, necessitating complete part replacement. Lens DED technology, however, provides a highly effective solution for repairing these components. By precisely depositing material only where needed, Lens DED can restore parts to their original specifications, significantly extending their service life and reducing the need for expensive replacements. 

  

2. Prototyping and Production

The aerospace industry frequently requires the production of complex geometries and parts that integrate multiple materials. Lens DED excels in this domain, enabling the creation of intricate designs that would be challenging or impossible with conventional manufacturing techniques. This capability makes Lens DED ideal for both prototyping and low-volume production of high-performance aerospace parts. Engineers can rapidly iterate on designs, test them in real-world conditions, and bring innovative products to market faster than ever before. 

  

3. Material Development

Material performance is critical in aerospace applications, where components must withstand extreme temperatures, pressures, and environmental conditions. Lens DED technology facilitates the development and testing of new materials and alloys tailored for specific aerospace applications. By allowing precise control over the material composition and microstructure, Lens DED enables the creation of parts with enhanced performance characteristics, such as increased strength, durability, and resistance to corrosion and wear. 

  

4. On-Demand Manufacturing

In the aerospace sector, maintaining a large inventory of spare parts can be both costly and inefficient. Lens DED technology offers a solution through on-demand manufacturing, allowing companies to produce critical components as needed. This approach not only reduces lead times and inventory costs but also ensures that parts are available when and where they are required, minimizing downtime and improving operational efficiency.  

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Conclusion 

Laser Engineered Net Shaping Directed Energy Deposition technology is revolutionizing the aerospace industry by providing advanced solutions for component repair, prototyping and production, material development, and on-demand manufacturing. As the industry

In today’s modern automotive sector, headlamps have evolved into distinctive design elements that contribute significantly to a vehicle’s overall aesthetic. Each brand strives for a unique lighting signature that reflects its identity and enhances its visual appeal while adhering to the performance standard required to ensure driver safety. One can efficiently design all exterior automotive lamps using LucidShape.

Designing a headlamp system that meets stringent regulatory requirements and delivers optimal light distribution is a complex, iterative process. Traditionally, engineers must meticulously define the geometries, curvatures, and rotations of each optical element. This involves a time-consuming cycle of input parameter adjustments, simulation, and analysis, often requiring numerous design iterations before achieving the desired output. This leads to prolonged development cycles, increased costs, and reduced efficiency.

LucidShape addresses this challenge with its innovative Functional Geometry feature where engineers can explicitly define the target light distribution they wish to achieve, instead of manually tweaking individual parameters. This represents a beneficial reverse engineering approach, streamlining the design process and enabling faster prototyping.

FunGeo Design Features

Functional geometry (FunGeo) adheres to the principle of ‘form follows function.’ Since determining precise curvatures of each facet of the reflector can be complex, LucidShape allows direct specification of desired light spread angles or distances. This approach focuses on achieving desired lighting performance by defining functional requirements rather than relying on mathematical calculation of curve shapes.

 

Fig 1. Depicts the two focal profile curves of the reflector that determine its curvature and the dialog box to define the spread parameters. The light distribution obtained corresponds to the specified spread parameters

A prominent trend in lighting design involves the utilization of lenses or reflectors with several small pillows or facets that allows for greater control over the light distribution. By incorporating a wider range of geometric design tools, LucidShape facilitates this design complexity.

FunGeo has 3 design tools to create reflectors and lens system based on the lamp application:

1. Procedural Surface: signal lights such as stop lamps, turn lamps, and rear lamps.
2. Poly Curve System: projector headlamps, LED Concentrators
3. Macro Focal: Low beam and High beam lamps, interior lighting.

For a signal lamp, the PS tool allows us to set parameters like spread angles, number of profiles or the reflector size. With this technique it is also possible to create several types of lenses which are used as outer optics in automotive head lamps.

Fig 2. Shows the geometry and input parameters for a signal stop lamp designed using the PS Rectangular Reflector tool and the luminance intensity plot after Monte Carlo ray trace is performed.

 

Low beam headlamps necessitate a distinct cutoff line in their light distribution. This sharp edge can be achieved using the concept of a MacroFocal (MF) object. This feature allows engineers to precisely control light distribution by defining spread for each facet, and cutoff angles essential for low beam functionality.

Fig 3. Design of a low beam Macro Focal reflector with specific spread parameters defined for each facet and the corresponding low beam light distribution.

Collimator LED lens used to concentrate or parallelize rays from a divergent light source is based on the poly curve system design with 4 profile curves. These collimators find application in high beam lamps and motorcycle headlamps.

 

Fig 4 . Depicts the four base curves of a poly curve system that determines the reflector’s shape. A LED collimator design based on PCS tool is used to collimate light rays from a divergent source.

 

The goal-oriented approach of this feature helps deliver accurate, optimization-ready designs right from the first attempt. Achieving optimal light output is no longer a maze of iterations. It significantly reduces development time and empowers engineers to prioritize innovation over time-consuming refinements.

In conclusion, the innovation in lighting requires solution that balance aesthetics and functionality. LucidShape’s design features empower engineers with performance-driven design capabilities, ensuring maximum efficiency. It facilitates the creation of diverse reflector systems for a wide range of automotive lighting applications and ensures that the final product meets the stringent safety and aesthetic requirements of the modern automotive landscape.

 

Classification based on the overall Landscape of Additive Manufacturing

The AM is broadly classified into 2 categories:

• Technology
• Materials

 

Figure (1): Classification based on the overall Landscape of Additive Manufacturing (Image Courtesy oftoof EOS GmbH)

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Technology

Technological Classification of Additive Manufacturing:

Today, Additive Manufacturing (AM) is not only available for industry grade applications but also for hobby printing thanks to learning- grade tabletop printing machines. Broadly there are 7 categories of AM processes worldwide while new techniques and processes are being introduced due to continuous emergence and expansion of this industry.

• VAT Photo – Polymerisation
• Material Jetting
• Binder Jetting
• Material Extrusion
• Powder Bed Fusion
• Sheet Lamination
• Direct Energy Deposition

 

VAT Photo – Polymerisation

VAT Photo – Polymerisation is an additive manufacturing process where a liquid photopolymer resin is selectively cured by a light source to build up a part layer by layer. The term “VAT” refers to the vat or container that holds the liquid resin during the printing process.

The VAT photo – polymerisation is further categorised into the following:

• Stereolithography (SLA)
• Digital Light Processing (DLP)
• Hybrid Photosynthesis Technology (HPS) [SLA + DLP]
• Liquid Crystal Display (LCD)
• Lubricant Sublayer Photo – Curing (LSPc)
• Programmable Photo Polymerisation (P3)
• Continuous Digital Light Manufacturing (CDLM)
• Continuous Liquid Interface Production (CLIP)

 

Material Jetting (MJ)

Material Jetting is an additive manufacturing process that works similarly to inkjet printing but instead of jetting ink, it deposits droplets of build material layer by layer to create a 3D object. Each layer is immediately cured or solidified using ultraviolet (UV) light, allowing for the creation of highly detailed and accurate parts.

The material jetting (MJ) is further categorized as follows:

• Material Jet Printing (MJP)
• Liquid Metal Jetting (LMJ)
• Polyjet (PJ)

 

Binder Jetting (BJ)

Binder Jetting is an additive manufacturing process that uses a liquid binding agent to selectively bind powder particles together to form a solid part. The process builds parts layer by layer, like other AM technologies, but it stands out for its ability to handle a wide range of materials and its relatively low cost.

The Binder Jetting (BJ) process is further categorized as:

1. Single Pass Jetting (SPJ)

 

Material Extrusion (ME)

Material Extrusion is an additive manufacturing process where a thermoplastic material is heated until it becomes semi-liquid and is then extruded through a nozzle to build up an object layer by layer. The extruded material solidifies and bonds with the previous layer, gradually forming the desired 3D shape.

 

Figure (2): Material Extrusion Process

The Material extrusion is further categorized into following:

• Fused Deposition Modelling (FDM)
• Fused Filament Fabrication (FFF)
• High Speed Extrusion (HSE)
• Independent Dual Extruder (IDEX)
• Cast in Motion (CIM)
• Atomic Diffusion Additive Manufacturing (ADAM)

 

Powder Bed Fusion (PBF)

Powder Bed Fusion is an additive manufacturing process where a heat source, typically a laser or electron beam, selectively fuses powdered material layer by layer to build a part. The process occurs in a controlled environment to ensure high precision and material properties.

The Powder Bed Fusion is further categorized into following:

• Laser Powder Bed Fusion (LPBF) further also known as:
  • Selective Laser Sintering (SLS)
  • Cold Metal Fusion (CMF)
  • Quantum Laser Sintering (QLS)
  • High Speed Sintering (HSS)
  • Direct Metal Laser Solidification (DMLS)
  • Selective Laser Melting (SLM)
  • Direct Metal Laser Melting (DMLM)
  • Hybrid Laser Powder Bed Fusion with CNC (HLPBF)

 

• Multi Jet Fusion (MJF)
• Selective Absorption Fusion (SAF)
• Electron Beam Melting (EBM)
• Mold Jet Technology (MJT)

 

Sheet Lamination

Sheet Lamination, also known as Laminated Object Manufacturing (LOM), involves layering sheets of material and bonding them together to form a solid part. Each sheet is precisely cut to match the cross-sectional shape of the part at a particular layer. The layers are bonded using adhesives, heat, or pressure, creating a cohesive structure.

 

Direct Energy Deposition (DED)

Direct Energy Deposition is an additive manufacturing process that uses focused thermal energy, such as a laser, electron beam, or plasma arc, to fuse materials by melting them as they are being deposited. This technology can work with various materials, including metals, ceramics, and composites, making it highly versatile for different industrial applications.

The Direct Energy Deposition (DED) is further categorized as follows:

• Laser Direct Energy Deposition (LDED)
• Hybrid Laser Direct Energy Deposition with CNC (HLDED)
• Rapid Plasma Deposition (RPD)
• Wire Arc Additive Manufacturing (WAAM)

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Materials

AM classifications based on Raw Material Form/Shape and Feed:

 

Extrusion Based Additive Manufacturing

Extrusion-based additive manufacturing is a process where a thermoplastic material is heated until it becomes semi-liquid and is then extruded through a nozzle to build up an object layer by layer. The extruded material solidifies and bonds with the previous layer, gradually forming the desired 3D shape.

 

Resin Based Additive Manufacturing

Resin-based additive manufacturing involves the use of liquid photopolymer resins that are selectively cured by a light source to form solid layers. These layers are built up sequentially to create a complete 3D object. The process is known for its high resolution and ability to produce intricate details and smooth surface finishes.

 

Powder Based Additive Manufacturing

Powder-based additive manufacturing involves spreading a layer of powdered material, which is selectively fused by an energy source to form a solid layer. The process repeats layer by layer until the entire part is built. The unfused powder supports the part during the build, eliminating the need for additional support structures.

 

Sheet Based Additive Manufacturing

Sheet-based additive manufacturing builds objects by stacking, bonding, and cutting sheets of material. Each sheet is cut to the desired shape using a laser or mechanical cutter and bonded to the previous layer to form the final 3D part. This method can utilize a variety of materials, including paper, plastic, and metal.

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Stay tuned to our Blog series to get further information on the above technologies in detail.

Overview

In the tire industry, precision and efficiency are paramount when producing high-quality tires that perform optimally on the road. With increasing pressure to innovate while maintaining cost-effectiveness, tire manufacturers are turning to 3D printing as a transformative solution. The combination of EOS Direct Metal Laser Solidification (DMLS) technology and the EOS M290 system is revolutionizing how tire mold sipes are produced, offering improved performance, reduced cycle times, and significant cost savings.

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The EOS DMLS Process: Advancing Tire Mold Production

EOS DMLS is a state-of-the-art metal 3D printing technology that uses a high-powered laser to fuse fine metal powders into solid metal parts, layer by layer, directly from a 3D CAD model. This additive manufacturing process allows for the creation of complex geometries that traditional methods, such as machining or casting, cannot achieve. In the context of tire mold sipes, this means manufacturers can produce intricate tread patterns and molds with greater precision, speed, and efficiency.

The EOS M290 system, a highly versatile and precise 3D printing platform, is specifically designed for industrial applications like tire mold production. Its capabilities make it the ideal system for manufacturing tire mold sipes with the accuracy and reliability required to meet industry standards.

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Why EOS DMLS and the M290 System Are Perfect for Tire Mold Sipes

• Complex Mold Designs Made Simple

  Traditional tire mold manufacturing methods can struggle to create intricate tread patterns due to the limitations of machining and casting. With the EOS DMLS process, the M290 system can print highly detailed and complex shapes that are impossible to achieve with conventional methods. This capability is crucial for producing advanced tire sipes—the patterns that play a critical role in improving tire performance, such as traction, durability, and handling.

• Precision and Customization

  The ability to create custom molds with high precision is one of the key benefits of 3D printing. The EOS M290 system enables tire manufacturers to experiment with different tread designs, optimizing them for various driving conditions. Whether it’s for high-performance tires or eco-friendly models, the M290 system ensures that every mold is crafted to exact specifications, delivering optimal tire performance and consistency.

• Faster Production and Shorter Lead Times

  Traditional tooling for tire molds can take weeks to manufacture, with long lead times that delay production schedules. The EOS M290 system drastically reduces these lead times by enabling rapid prototyping and direct production of the final mold. Once the design is ready, the mold can be produced in a matter of days, not weeks. This faster production capability allows tire manufacturers to quickly respond to market demands and reduce time-to-market for new tire models.

• Cost-Efficiency

  Traditional mold-making processes often result in material waste, as large portions of the mold material are machined away. With 3D printing, the EOS M290 system uses only the material needed to build the mold, minimizing waste and lowering production costs. This cost-efficient approach is particularly valuable for tire manufacturers who need to balance precision and performance with cost-effectiveness.

• Improved Tool Durability

  The EOS DMLS process produces molds with enhanced durability compared to traditional methods. With precise control over the material properties, tire manufacturers can produce molds that are not only strong but also resistant to wear and tear over time. The result is longer-lasting tools that require less maintenance, ensuring that tire production remains consistent and high-quality.

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EOS M290: The Ideal System for Tire Mold Sipes Production

The EOS M290 system is specifically designed to meet the demands of industrial 3D printing, making it the perfect choice for tire mold production. This mid-size 3D printer offers high precision and a broad range of metal materials, including Maraging Steel, Tool Steel, and Stainless Steel, which are ideal for creating durable and high-performance tire molds.

Fig. (1): Build plate with tire mould sipes from EOS M290 system|(Image Courtesy: EOS website)

 

With the EOS M290 system, tire manufacturers can harness the full potential of DMLS technology to produce molds that are more precise, more durable, and more efficient than those made with traditional methods. The system’s high productivity and scalability make it suitable for both prototype and large-scale production, allowing manufacturers to streamline their processes and increase output.

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The Impact of EOS DMLS on Tire Manufacturing

The ability to produce highly detailed tire molds with complex geometries using EOS DMLS technology and the M290 system has had a profound impact on the tire industry. By reducing production times, lowering costs, and increasing precision, tire manufacturers are now able to meet the ever-growing demands for performance, durability, and customization.

Additionally, the flexibility offered by 3D printing allows manufacturers to produce molds in small batches, experiment with new tread patterns, and rapidly prototype new tire designs—all without the need for expensive tooling changes or long production delays.

Fig. (2): Marigo Tire Mold Insert printed using EOS DMLS system|(Image Courtesy: EOS website)

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Conclusion

The tire industry is experiencing a shift towards more efficient, cost-effective, and innovative production methods, and EOS DMLS technology with the M290 system is at the forefront of this transformation. By enabling the creation of high-precision tire mold sipes with faster lead times, reduced costs, and improved durability, the M290 system is revolutionizing the way tire molds are manufactured.

For tire manufacturers looking to stay ahead of the curve and enhance their production processes, embracing 3D printing with EOS DMLS technology is essential. The future of tire mold production is here, and it’s powered by the EOS M290 system.

Fig. (3): EOS M290 system suitable for mould manufacturing|(Image Courtesy: EOS website)