The lightweight hood hinge project aims to manufacture automotive hinges using metal 3D printing (metal additive manufacturing) with the goal of reducing weight and integrating pedestrian protection features. The project is a collaboration between EDAG Engineering GmbH, Voestalpine Additive Manufacturing Center, and Simufact Engineering GmbH. The project's objective is to redesign the hinge to achieve lightweighting and enhanced safety in a single component.
Traditional hinge manufacturing
Materials and machines
Traditionally, hinges are manufactured from aluminum using conventional manufacturing machines.
Manufacturing characteristics
Components produced using traditional methods are generally heavier, leading to higher carbon emissions. Parts must be assembled from many small components (approximately 40 parts), increasing assembly costs and tooling. Furthermore, adding new functions to the product without compromising quality or increasing costs is not feasible.
(On the left is the 3D printed metal hinge and on the right is the traditional hinge)
Metal 3D printing hinges with SLM 280
Materials and machines
With metal additive manufacturing method, the hinge is produced using SLM 280 Twin, made from Nickel IN718 alloy
(SLM 280 2.0)
Learn more: Current popular SLM metal 3D printer lines
Manufacturing characteristics
Metal 3D printing has enabled us to reduce component weight by approximately 50%. The number of parts in the component has been decreased from around 40 to just 2, significantly reducing post-processing costs. This method also allows for complex designs without increasing costs, while optimizing the structure for weight advantages
Watch more: SLM SOLUTIONS AND PORSCHE ACHIEVE HIGH-PERFORMANCE E-DRIVE HOUSING ON NGX XII 600
Pedestrian protection function of metal 3D printed hinges
Force absorption design
The hinge can be designed to deform in a controlled manner upon impact. This deformation absorbs a portion of the impact energy, reducing the force transmitted to the pedestrian. By using Nickel IN718 alloy and additive manufacturing, the hinge can be structurally optimized to achieve the best force absorption capabilities
Integrated safety system
The LightHinge+ 3D printed hinge uses a complex kinematic mechanism combined with an optimized structure and a custom-made self-deploying system. This system is activated similarly to an airbag. Its purpose is to automatically deploy the hinge to lift the hood, protecting pedestrians in the event of a collision
Simulation and deformation compensation technology
Using simulation software like Simufact Additive, engineers can predict and optimize the hinge's deformation during the printing process to reduce the number of physical tests. Another unique feature of Simufact Additive is active deformation compensation, where the hinge's deformation during printing is predicted, and the software automatically adjusts the print geometry to compensate for the expected deformation. This minimizes the geometric deviation of the printed hinge from the original design
Advanced materials
Nickel IN718 alloy offers superior mechanical properties, including high strength and better tolerance under impact conditions compared to aluminum. This enhances the hinge's effectiveness in absorbing impact energy and minimizing pedestrian injuries
Development and optimization process
Redesigned for metal 3D printing
EDAG engineers have redesigned the hinge system to be compatible with metal 3D printing. They have applied biological principles to determine the minimum material requirements and achieve a weight advantage of approximately 50%
Geometric structure optimization
Voestalpine Additive Manufacturing Center has collaborated to optimize the support structure. Dr. Eric Klemp has calculated the minimum material requirements for the hinge
Simulation and deformation management
Simufact Additive simulation software has been used to predict and manage deformation and residual stress. Partners have relied on this simulation to negatively deform the part geometry to minimize shape deviations of the hinges after printing compared to the target geometry.
Project results
The project has successfully demonstrated the practical application of metal 3D printing in automotive manufacturing. Voestalpine Additive Manufacturing Center has reported resource-efficient and cost-effective production with minimal post-processing. The LightHinge+ hinge achieves optimal weight reduction and integrated pedestrian protection, produced without tooling and with minimal rework
Why choose the SLM 280 printer for automotive parts?
The SLM 280 printer is one of the most advanced additive manufacturing technologies today. This printer uses Selective Laser Melting (SLM) technology to create metal parts with high precision and complex structures. In particular, the SLM 280 can print with superalloys such as IN718, providing superior strength and heat resistance.
Benefits of using the SLM 280 in automotive part production:
Weight reduction: Metal 3D printing can reduce part weight by about 50% compared to traditional methods, thanks to the ability to optimize structures and use lightweight but durable materials.
Structure and design optimization: SLM technology allows for the creation of complex designs and optimized structures using biological principles, which is not possible with traditional manufacturing methods.
Reduced part count: The number of parts in a component is reduced from about 40 to 2, significantly reducing assembly costs and tooling.
Reduced post-processing costs: With the SLM 280, post-processing costs can be significantly reduced, thanks to the ability to create parts with high precision and minimal rework needed.
Source: Project LightHinge+ demonstrates practical potential of Additive Manufacturing (metal-am.com)
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