Recent media reports confirm that leading auto companies are increasingly adopting 3D printing for critical components. The latest focus involves a new set of high-performance electric drive units, pushing the boundaries of automotive engineering.

Optimizing Electric Drive Housings

This 3D printing project features a fully integrated electric drive housing. It contains both an electric motor and a two-speed aluminum alloy gearbox. Remarkably, this device delivers enough power for supercar configurations. By moving away from traditional casting, engineers have created a production process that is as innovative as the product itself.

The Laser Metal Fusion (LMF) Process

Engineers utilize the laser metal fusion (LMF) process to achieve these results. During this procedure, a precise laser beam melts aluminum alloy powder layer by layer according to the part’s contour. This additive approach allows the team to optimize heat transfer significantly. Furthermore, it enables real-time load tests during the development phase.

Superior Strength and Lightweight Performance

The final 3D-printed housing is 10 percent lighter than traditional castings. Although the walls are only 1.5 mm thick, the integrated grid structure increases overall stiffness. This honeycomb design provides much greater strength than standard parts. Similar benefits apply to 3D-printed pistons. These pistons feature internal cooling ducts that are impossible to create using conventional production methods.

Retrofitting Classic Cars and Future Trends

3D printing technology makes customizing spare parts for older models incredibly easy. For example, disassembling and upgrading a classic car’s drivetrain with 3D-printed equipment can take just one day. While additive manufacturing is not yet the mainstream mode for mass production, technology is evolving rapidly. Many car companies now refer to this process as “additive manufacturing” to highlight its role in advanced engineering.

Barry Zeng
Senior Manufacturing Engineer, Shanghai Yunyan Prototype & Mould Manufacture Factory
Specializing in high-performance aluminum 3D printing and automotive DFM reviews.