Bringing a new approach to manufacturing, 3D technology is highly demanded among autumotive leaders. Joining to these leaders, Renault Trucks used this technology in Euro 6 engine.
Continuing development projects in order to preserve its leadership, Renault Trucks start using 3D which is one of the most important innovations of recent years. Taking steps in that sense, the firm started additive manufacturing process with its engine system.
Although the complete engine was already designed virtually, rocker arms and camshaft bearing caps were manufactured by metal 3D printing and successfully bench-tested for 600 hours inside a Euro 6 engine. “The aim of this project is to demonstrate the positive impact of metal additive manufacturing on the size and weight of an engine. This process has enabled us to reduce the weight of a 4-cylinder engine by 120 kg or 25%”, explained Damien Lemasson, project manager at Renault Trucks. “The tests we have carried out prove the durability of engine components made using 3D printing. It’s not just cosmetic.”
Metal additive manufacturing opens up new development opportunities for thermal engines. This printing process, which works by adding materials layer after layer, can be used to create complex organic forms, as well as optimizing the sizing of parts and reducing the number of assembly operations and therefore the number of components in an engine. “Additive manufacturing releases us from constraints and unlocks the creativity of engineers. This procedure is a source of disruptive technology for the engines of tomorrow, which will be lighter and more functional, thereby offering optimal performance,” Damien Lemasson added. The number of components in the DTI 5 engine has been reduced by 25%, making a total of 200 fewer parts
In the short-term, this manufacturing procedure can be used for highly specific applications or small runs. Following on from these successful initial tests, engineers at Renault Trucks will be continuing their work on this manufacturing process to further increase the performance and functionality of truck components.