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Customer |
Cylinder head (R4 16 V), water-cooled
In the first stage, a wide range of different channel combinations were to be tested to optimise combustion. If additional conceptual requirements are added to the comparable series' characteristics, the number of Rapid Prototyping techniques available decreases. Normally, it is impossible to achieve features comparable to those produced by ingot molding with sand casting, because the procedure's cooling characteristics are totally different. Nevertheless, these parameters can be achieved with the help of directional solidification and mold cooling - a technology patented by the ACTech GmbH.
For this special technology, in co-operation with the customer, the cylinder head's outer geometry was 'frozen' and represented in the casting mold using modelling equipment. To obtain the different channel geometries, the Croning® molding material was laser-sintered. This way, almost twenty different channel geometries and combinations were physically checked in a very short time. Afterwards, the channel geometry finally selected was produced in a small series of 70 pieces at ACTech in order to bridge the gap until the delivery of the pre-series molds.
On the one hand using Rapid Prototyping technologies, the customer was able to dramatically reduce engineering leadtime. On the other hand, it was also possible to reach a wide range of variants implemented in a quick and low cost way.
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