Dec 8, 2015 | By Benedict
Stories of 3D printed steering wheels, seat interiors and prototype brake pedals are a dime a dozen these days—on our in-tray, at least. But a 3D printed plastic engine may sound unusual, if not downright impossible, to some skeptical ears. The concept of an all-plastic car engine has actually been floating around for a few decades, thanks to the innovative strides taken by visionary engineer Matti Holtzberg. Solvay Specialty Polymers has announced today that the Polimotor 2 project, led by Holtzberg, will feature a 3D printed fuel intake runner, produced by composite parts manufacturer Arevo Labs, and made from Solvay’s KetaSpire polyetheretherketone (PEEK) material. The Polimotor 2 project, sponsored by Solvay, aims to produce a next-generation, all-plastic engine for competitive racing. The engine, which is now all set to employ the new 3D printed fuel runner, is expected to be unveiled in 2016.
“The intake runners in the original Polimotor engine were made from aluminum, but today the automotive industry relies almost entirely on injection-molded nylon,” said Holtzberg. “That choice of materials is changing now too, as automakers seek innovative new alternatives like Solvay’s PEEK that can withstand rising under-the-hood temperatures caused by the growing use of turbochargers and engine downsizing, both of which are resulting in higher specific power outputs.”
PEEK is highly resistant to automotive fuels, and can brave continuous-use temperatures of up to 240°C (464°F). Since the Polimotor 2’s fuel intake runner will reach temperatures of around 150°C (302°F) near the pistons, the material’s stubborn resistance to fuel and heat should stand it in good stead when the engine is finally put to the test next year.
The intake runner of an engine is typically integrated with the plenum: a pressurized chamber which distributes a constant amount of air flow between the air inlet and cylinders. The intake runner’s specific function is to inject fuel into the air stream at the precise moment when it enters the engine. The quality of an engine’s intake runner can directly affect the machine’s horsepower. There were several advantages in replacing the previous aluminum runner with the 3D printed alternative, such as a 50% weight reduction.
“The convergence of 3D printing with Solvay’s PEEK polymer technology in this application underscores how truly cutting-edge the Polimotor 2 project is,” said Brian Baleno, global automotive business manager at Solvay. “Neither of these technologies existed in the ’80s when Matti Holtzberg developed the first Polimotor engine; and now, with this runner, we see one of the very first carbon fiber-filled PEEK parts to be fabricated with the additive manufacturing process. That signals a whole new range of possibilities for automakers seeking lighter, but high-performing alternatives to metal.”
The all-plastic, partially 3D printed Polimotor 2 engine will weigh between 138 and 148lbs (63-67kg), which is around 90lbs (41kgs) less than the standard metal alternative.
Posted in 3D Printing Application
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