How an Engine Hood Light Hinge Was 3D Printed

Active hinge systems for engine hoods are crucial for pedestrian safety, but their complexity and weight pose significant challenges. Traditional manufacturing methods like stamping, casting, or forging are cost-effective only for large-scale production, making small runs of 80 to 30,000 units economically unfeasible. Additionally, the limited assembly space in sports cars makes it difficult to use conventional sheet-metal methods, which often result in heavy hinges that add considerable weight to the vehicle.

System: NXG XII 600

System: SLM®125

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IMPROVED FUNCTION COOLING THROUGH INTEGRATED LATTICE

To tackle these challenges, EDAG, voestalpine Additive Manufacturing, and simufact engineering teamed up to optimize the engine hood hinge using additive manufacturing (AM). The collaboration focused on achieving significant weight reduction, enhancing functional integration, and improving cost efficiency. By leveraging the design flexibility of AM technology, the team developed a more efficient and innovative solution that surpassed the limitations of traditional manufacturing.

Key Improvements Include:

Significant Weight Savings: 52% lighter than conventional sheet metal hinges.
Enhanced Efficiency: Material use and post-processing steps drastically reduced.
Compact Design: Ideal for the limited assembly space in sports cars and high-performance vehicles.

The successful collaboration showcases the potential of additive manufacturing to revolutionize vehicle component design, offering automotive manufacturers a powerful tool for meeting stringent safety standards while achieving substantial weight and cost savings. Download the full case study to learn more.

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