'From powder to a component': Audi uses 3D printer to produce classic Grand Prix sportscar

Audi’s Toolmaking unit has produced a model of the historical Grand Prix sportscar ‘Auto Union Typ C’ from the year 1936 using a 3D printer. The company is now examining further possible applications of metal printers for the production of complex components. At the same time, Audi is creating important synergies with toolmaking in other parts of the Volkswagen Group.

“We are pushing forward with new manufacturing technologies at Audi Toolmaking and at the Volkswagen Group,” stated Dr Hubert Waltl, Audi’s board of management member for production and head of toolmaking at the Volkswagen Group. “Together with partners in the area of research, we are constantly exploring the boundaries of new processes. One of our goals is to apply metal printers in series production.”

The Volkswagen Group has a total of 14 toolmaking units in nine countries. Under the leadership of Dr Waltl, cooperative ventures have been arranged for research and development. The first focus of the cooperation is the implementation of metallic 3D printing and 3D printing in the sand‑printing method. Audi Toolmaking has now used metal printing to produce all the metallic parts of the Silver Arrow model ‘Auto Union Typ C’ on a scale of 1:2.

For the same, a selective-sintering laser melted layers off metallic powder with a grain size of 15 to 40 thousandths of a millimetre, roughly half of the diameter of a human hair. The process therefore allows the production of components with complex geometries, which with conventional methods could either not be produced or only with great difficulties. Audi Toolmaking is currently using 3D printing to produce components out of aluminum and steel. At present, this process can be used to produce shapes and objects with a length of 240 millimetres and a height of up to 200 millimetres. These printed components achieved a higher density than components made by die casting or hot forming.

Also read: How 3D printing could revolutionise the car industry