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.
As the design division of Materialise, . MGX works with additive manufacturing technologies and top designers, architects and artists to produce architectural models, art pieces and other custom- made projects, as well as a range of exceptional lighting objects, furniture, interior goods and accessories - all with a degree of detail, complexity and speed that cannot be offered by other production techniques. The . MGX influence Renault was able to integrate the . MGX philosophy into the concept car, creating a unique design using the natural laser sintering surface with backlighting, in the same way that Materialise does with its own . MGX product line. The lower dashboard with the . MGX logo and the ceiling of the car were made from PA. Additionally, other light emitting components such as the two decorative exterior front lights were made through additive manufacturing. Their complexity was too high to mill these components easily in PMMA; therefore a new transparent stereolithography material was used. The link with . MGX allowed Renault to create an even greater impact in the design world with the Renault Ondelios concept. The partnership with . MGX resulted in an amazing amount of coverage for Renault in various design magazines. Also thanks to Materialise Mammoth machines, PGO pushed the boundaries of additive manufacturing to make its Hemera project a reality. The project commenced in March 2008, and after the development phase, the first 3D files were ready only three months before the show. PGO made an assembly of the whole car using stereolithography parts. After some small modifications to the parts, the stereolithography components were used as master patterns to make moulds, enabling PGO to produce three sets of parts in order to build the first three vehicles, and this in the shortest time frame. Materialise has definitely taken the lead in the use of additive manufacturing for concept cars. They not only take care of the component production, but as a company and their link with design they are a source of inspiration for vehicle designers around the world. This allows not only using additive manufacturing as a manufacturing method, but really exploiting the inherent advantages for concept vehicles to the greatest extent. Can Materialise also inspire you? more information? click here!