In cooperation with its partners Mahle and Trumpf, Porsche is establishing a new milestone in the use of additive manufacturing processes for highly-stressed drive components.
3D printing technology is already used at the sports car manufacturer in prototype construction, manufacturing spare parts for classic sports cars as well as in other areas. For the first time, the pistons for the high-performance engine of the 911 flagship model, the GT2 RS, are now being produced with a 3D printer. Auto Car Engine Oil Filter
3D printing allows the pistons to be manufactured with a structure that is optimised for the loads acting on the pistons. As a result, the pistons from the advance development project weigh ten percent less than the forged series production pistons. They also have an integrated and closed cooling duct in the piston crown that could not have been produced by conventional methods. “Thanks to the new, lighter pistons, we can increase the engine speed, lower the temperature load on the pistons and optimise combustion,” explains Frank Ickinger from the advance drive development department at Porsche. “This makes it possible to get up to 30 PS more power from the 700 PS biturbo engine, while at the same time improving efficiency.”
There are a number of different technologies for 3D printing. All are based on the principle that the components are built up layer by layer without the need to previously manufacture a special tool or mould. Practically any geometric shape can therefore be realised. The printer can be fed with the design data directly from the computer. Additive manufacturing processes are thus ideal for producing structures that have been designed and optimised by means of artificial intelligence (AI).
The pistons of the 911 GT2 RS were manufactured from high-purity metal powder using the laser metal fusion process (LMF). Here, a laser beam heats and melts the powder surface corresponding to the part contour. Porsche initiated the joint project together with cooperation partners Mahle and Trumpf. The quality and performance capability of the components were validated using measurement technology from Zeiss.
Porsche already uses additive manufacturing processes in several areas. For example, a 3D-printed bodyform full bucket seat has been available since May for the model series 911 and 718. Here, the central section of the seat, in other words the cushion and backrest surfaces, is partly produced by a 3D printer. Customers will be able to choose between three firmness levels (hard, medium, soft) for the comfort layer in future.
Porsche Classic also uses additive processes to reproduce plastic, steel and alloy spare parts that were previously no longer available. A release lever for the clutch of the Porsche 959, for example, today comes from a 3D printer. Around 20 reproduced parts for Porsche classic models are currently manufactured using additive processes. This manufacturing technology is also technically and economically interesting for Porsche for special and small series as well as motorsports. 3D printing therefore offers significant potential for Porsche with regard to product and process innovations, which will in turn allow customers to benefit from fascinating and individual products.
Porsche presents an innovative alternative to conventional bucket seat upholstery with the concept study.
In the factory of the future, innovative production methods will bring major advantages.
Experts in Weissach use 3D printing and innovative materials to design the sports cars of tomorrow.
For collectors, the unavailability of spare parts can lead to problems. Porsche Classic has a solution.
© 2024 Dr. Ing. h.c. F. Porsche AG.
* Where values are indicated as ranges, they do not refer to a single, specific vehicle and are not part of the offered product range. They are only for the purposes of comparison between different vehicle types. Additional equipment and accessories (add-on parts, tyre formats etc.) can change relevant vehicle parameters such as weight, rolling resistance and aerodynamics. These factors, in addition to weather, traffic conditions and driving behaviour, can influence the fuel/electricity consumption, CO2 emissions, range and performance values of a vehicle.
** Important information about the all-electric Porsche models can be found here.
1. All information offered on Porsche Newsroom, including but not limited to, texts, images, audio and video documents, are subject to copyright or other legislation for the protection of intellectual property. They are intended exclusively for use by journalists as a source for their own media reporting and are not intended for commercial use, in particular for advertising purposes. It is not permitted to pass on texts, images, audio or video data to unauthorised third parties.
Drag Link Assy 2. Use of Newsroom content for book projects (or similar commercial use) is not permitted, particular with regards to images. Any potential usage must be approved beforehand by Dr. Ing. h.c. F. Porsche AG. To discuss licencing requests for book projects please email: archiv@porsche.de 3. All logos and trademarks mentioned on Porsche Newsroom are trademarks of Dr. Ing. h.c. F. Porsche AG (hereinafter: Porsche AG), unless otherwise stated. 4. All contents of Porsche Newsroom are carefully researched and compiled. Nevertheless, the information may contain errors or inaccuracies. Porsche AG does not accept any liability with respect to the results that may be achived through the use of the information, in particular with respect to accuracy, up-to-dateness and completeness. 5. Insofar as Porsche Newsroom provides information concerning vehicles, the data refers to the German market. Statements concerning standard equipment and statutory, legal and tax regulations and repercussion are valid for the Federal Public of Germany only. 6. With respect to the use of Porsche Newsroom, technical faults such as, delays to news transmission, cannot be ruled out. Porsche AG does not accept any liability for any resulting damage. 7. Insofar as Porsche Newsroom provides links to the internet sites of third parties, Porsche AG does not accept any responsibility for the content of the linked sites. On using the links, the user leaves the Porsche AG information products. 8. In agreeing to these rights of use, the user shall be obliged to refrain from any improper use of Porsche Newsroom. 9. In the event of improper use, Porsche AG reserves the right to block access to Porsche Newsroom. 10. Should one or more provisions of these terms and conditions be or become invalid, this shall not affect the validity of the remaining provisions.