A dditive manufacturing can be described as the use of layered-based manufacturing technologies such as stereolithography, laser sintering and fused deposition modelling to produce final production components. More and more car manufacturers are using the benefits of additive manufacturing in the production of concept cars. The process opens a new world of design freedom. Secondly, the use of these technologies allows concept cars to be built faster than the traditional methods. Furthermore it becomes possible to personalise designs. Materialise is Europe's largest service bureau in additive manufacturing, having unique competences in the field. The company runs the world's largest single- site additive manufacturing plant in Leuven, Belgium. The position of Materialise is unique in the manufacture of concept vehicles in the automotive sector. The company has a unique set of software solutions to optimise files after design and Mammoth stereolithography machines of more than 2000mm large to build large parts in one single piece. Materialise can offer the inspiration of the . MGX brand and also has a broad knowledge of additive manufacturing. The combination of all of these elements allows car designers to reconsider many of today's limitations in car design. The car can be designed without traditional manufacturing constraints of that used to be present. Several examples of recent concept cars that used additive A revolution in the creation of concept cars By Jurgen Laudus, Materialise success Manufactured
manufacturing at Materialise are currently available. The Pininfarina Sintesi was shown at the Geneva Motor Show in 2008. The new car design forms and futuristic approach that characterize the Sintesi, exclude the use of traditional manufacturing technologies. The complexity of the IP, combined with the translucent aspect, required the use of additive manufacturing, as no other technology would have allowed the same design creativity. Due to its complexity, the radiator was also manufactured by stereolithography. The production of the smaller components such as the roof antenna and remote controller show the endless customisation possibilities of additive manufacturing. Concept car experience The Pininfarina Sintesi was the first concept car that not only uses additive techniques but really exploits all the advantages of additive manufacturing. The Citroën Hypnos is a functional one- off car where additive technologies are the only production method to manufacture a design of such a complexity. The whole interior is built using additive manufacturing technologies. This process was again only possible with the patented Materialise Mammoth machines, a stereolithography technology that can build parts with dimensions of 2100mm x 700mm x 800mm in a single piece. Such projects require dedicated skills in additive manufacturing in order to provide the desired level of added value. These services include a mix of design, R& D, engineering, CAD possibilities, material selection, and technical solutions to combine both design and functionality. In the Renault Ondelios concept, Renault was looking for partners to co- brand the car in a way that would add value to the car's style and design. The answer to this was . MGX by Materialise.