California based motor companyCzinger车辆is working with Motorsport & High Performance Automotive (HPA) gearbox production specialistsXtrac, to produce a topology-optimized and additively manufactured gearbox.
The 3D printed automated 7-speed semi-sequential gearbox, billed as an industry first, will be incorporated into Czinger’s 21C Hypercar. The gearbox offers sub-100ms shifts, the highest torque transmitted per mass of gearcase for any road-legal vehicle, dual barrel gear actuation, and a 48V- electrically actuated twin barrel system which is said to make it the fastest single clutch synchromesh gearbox in existence.
与专有铝一起使用独特的打印过程来生产变速箱。据称，这一过程促进了大量的体重节省，强大的结构性能，高生产质量和有效的印刷时间。此外，此AM过程消除了工具的需求，减少开发时间并允许进行实时设计改进。
“We are proud to team Czinger’s world-class engineers with those at Xtrac,” commented Czinger Co-Founder and SVP Operations Lukas Czinger. “Together, we have developed an incredible industry first, gearbox that is truly at the pinnacle of performance. We can’t wait to shatter more track records as we utilize this system in 21C”.
XTRAC首席执行官阿德里安·摩尔（Adrian Moore）称该项目为“开创性”，Xtrac“很高兴通过创建这些3D打印的套管来处于尖端变速箱制造的最前沿”。摩尔继续说：“对于我们的工程师紧密合作，将这种尖端的创新栩栩如生，这是非常有趣的，非常令人兴奋。”
21c超级跑车
The gearbox will be introduced into Czinger’s 21C Hypercar, a $2 million vehicle which leverages AM technology for a number of its components.
To produce the car, Czinger utilized sister firmDivergent Technologies’不同的自适应生产系统（DAPS）。小贩本质上是自动硬件软件汇编平台结合了3D打印和生成设计，提供了传统汽车生产过程的端到端替代方案。DAPS能够以最少的人工干预能够使用计算工程，打印和组装汽车制造，从而使同一台机器上的多个不同的汽车模型生产，同时允许快速设计迭代。
DuringGoodwood 20223D打印行业与Czinger Vehicles的创始人Kevin Czinger进行了交谈，后者透露，HyperCar的1,250马力HyperCar的底盘和悬架系统几乎完全是印刷的。“如果您查看底盘本身，几乎所有的框架结构都是使用DAPS设计，打印和组装的。与整个悬架系统一样，除了减震器之类的东西外，所有3D都打印了。我想说的是引擎的感应和排气元素，它们也是3D印刷的，” Czinger强调。
21C的V8发动机也被印刷的“ Motornodes”固定在适当的电动机上。此外，DAPS打印的“ Brakenodes”允许将卡钳集成到其制动立柱中，从而减少40至50％的零件计数和40％的体重。
AM and the automotive industry
Czinger并不是唯一一家使用AM技术来生产其车辆关键组件的汽车公司。在2021年，Rodin Cars, a New Zealand-based automotive manufacturer, announced that its ‘FZERO’ hypercare was set to incorporate a3D打印变速箱。罗丹与美国3D打印机制造商合作3D系统’Application Innovation Group(AIG) to produce the gearbox, leveraging a DMPFactory 500 system。
At the time, this gearbox was believed to be the first of its kind, offering a unique eight-speed sequential transmission system. 3D Systems claimed that, given its complex internal galleries, thin-wall bearing structure, and overall weight of just 68 kilograms, the gearbox couldn’t have been manufactured in any other way.
Elsewhere, in 2022 British sports car manufacturer阿斯顿·马丁介绍了一个新的敞篷跑车，其独特3D打印后组件produced by Divergent Technologies and its DAPS system. In the rear of its DBR22 model, Aston Martin integrated a support structure composed of multiple 3D printed aluminum parts bonded together, yielding a significant weight saving. “Divergent is proud to be working with Aston Martin Lagonda and other major global OEMs to transform the future of automotive design and engineering”, commented Kevin Czinger.
Subscribe to the3D打印行业newsletterto ensure you keep up with the latest 3D printing news. You can also follow us onTwitter, like ourFacebook页面，并订阅3D打印行业Youtubechannel to access more exclusive content.
Are you interested in working in the additive manufacturing industry? Visit3D Printing Jobs查看可用角色的选择并启动您的职业生涯。
特色图片显示了Czinger和Xtrac的3D打印变速箱。通过Shamin Abas的照片。
