California based motor organization Czinger Motor vehicles is doing work with Motorsport & Superior Efficiency Automotive (HPA) gearbox generation experts Xtrac, to generate a topology-optimized and additively made gearbox. 

The 3D printed automatic 7-velocity semi-sequential gearbox, billed as an marketplace first, will be integrated into Czinger’s 21C Hypercar. The gearbox features sub-100ms shifts, the best torque transmitted per mass of gearcase for any street-lawful car or truck, dual barrel gear actuation, and a 48V- electrically actuated twin barrel process which is said to make it the swiftest single clutch synchromesh gearbox in existence.

A exclusive printing system is made use of together with proprietary aluminum to develop the gearbox. It is claimed that this course of action has facilitated significant excess weight savings, powerful structural functionality, significant production high quality, and productive printing instances. What’s more, this AM system has removed the need to have for tooling, lessening advancement situations and making it possible for for actual-time style and design advancements to be built.

“We are happy to crew Czinger’s earth-class engineers with people at Xtrac,” commented Czinger Co-Founder and SVP Operations Lukas Czinger. “Together, we have designed an extraordinary sector first, gearbox that is genuinely at the pinnacle of effectiveness. We can’t wait to shatter more track records as we employ this program in 21C”.       

Xtrac CEO Adrian Moore named the undertaking “groundbreaking”, with Xtrac “pleased to be at the forefront of chopping-edge gearbox production by creating these 3D printed casings”. “It has been extremely intriguing and extremely stimulating for our engineers operating carefully alongside one another to bring this chopping-edge innovation to existence,” ongoing Moore.

Front view of Czinger and Xtrac's 3D printed gearbox. Photo via Shamin Abas
Front perspective of Czinger and Xtrac’s 3D printed gearbox. Image by means of Shamin Abas.

The 21C Hypercar

The gearbox will be introduced into Czinger’s 21C Hypercar, a $2 million car which leverages AM technological innovation for a range of its factors. 

To produce the automobile, Czinger utilized sister organization Divergent Technologies’ Divergent Adaptive Output Technique (DAPS). DAPS is effectively an automatic hardware-software assembly platform which combines 3D printing and generative style to supply an finish-to-conclusion option to the standard automotive production processes. Able of computational engineering, printing, and  assembling automotive builds with nominal human intervention, DAPS enables the production of several distinctive vehicle models on the similar machine, while permitting for speedy structure iteration.

For the duration of Goodwood 2022, 3D Printing Field spoke to Kevin Czinger, the founder of Czinger motor vehicles, who uncovered that the 1,250 horsepower hypercar’s chassis and suspension procedure is virtually totally 3D printed. “If you search at the chassis by itself, just about all the frame composition is built, printed and assembled making use of DAPS. As is the entire suspension system, other than items like shock absorbers, which is all 3D printed. I’d say the induction and exhaust aspects of the engine, they are all 3D printed as well”, highlighted Czinger. 

The 21C’s V8 motor is also boosted by electrical motors held in place by printed ‘MotorNodes’. In addition, DAPS-printed ‘BrakeNodes’ permits calipers to be built-in into its brake uprights, yielding a 40 to 50% portion count reduction and 40% excess weight price savings.

AM and the automotive industry 

Czinger is not the only automotive organization who have utilized AM technological innovation in the creation of key elements for their vehicles. In 2021, Rodin Vehicles, a New Zealand-centered automotive producer, announced that its ‘FZERO’ hypercare was set to integrate a 3D printed gearbox. Rodin partnered with US 3D printer manufacturer 3D TechniquesApplication Innovation Team (AIG) to create the gearbox, leveraging a DMP Manufacturing facility 500 procedure. 

At the time, this gearbox was thought to be the first of its kind, giving a special eight-speed sequential transmission process. 3D Methods claimed that, supplied its sophisticated inside galleries, skinny-wall bearing composition, and general bodyweight of just 68 kilograms, the gearbox could not have been produced in any other way.   

In other places, in 2022 British sports vehicle maker Aston Martin launched a new roadster featuring a distinctive 3D printed rear assembly manufactured by Divergent Systems and its DAPS program. In the rear of its DBR22 model, Aston Martin integrated a support composition composed of numerous 3D printed aluminum sections bonded with each other, yielding a sizeable pounds conserving. “Divergent is happy to be working with Aston Martin Lagonda and other key international OEMs to completely transform the long run of automotive style and design and engineering”, commented Kevin Czinger.  

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Featured impression exhibits Czinger and Xtrac’s 3D printed gearbox. Picture by way of Shamin Abas.


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