Lyon, France – A team of Renault Trucks engineers and designers is working on an additive manufacturing process – metal 3D printing – that is set to boost the performance of engines. The Renault Trucks Lyon Powertrain Engineering department has built a prototype 4-cylinder engine using 3D printing.
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 120kg or 25%,” explains 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. The process can be used to create complex organic forms and optimize part sizes, reducing the number of assembly operations and 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,” Lemasson adds.
Metal 3D printing could reduce engine sizes, giving trucks higher payload capacities and fuel economy.
In the short-term, this manufacturing procedure can be used for 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.
Source: Renault Trucks