AutomotiveDigital Additive Mass Production (DAMP)Distributed ManufacturingMetal Additive Manufacturing

Shining 3D’s Metal 3D Printed Ford Mustang Exhaust Pipe Weighs 65% Less

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Leading desktop, professional and industrial 3D printer manufacturer Shining 3D worked with an undisclosed car customization company to design and produce a fully 3D printed exhaust pipe using its EP-M250 metal 3D printers.  The exhaust pipe has already been installed and used in an assembly trial on a Ford Mustang.

Due to the limitation of conventional soldering technology, traditional exhaust pipe manufacturing is limited in terms of optimizing airflow through complex geometries. Complex design is difficult to implement, which means that in the current market, the shape of the gas flow in auto exhaust pipes is is limited to basic graphic desgin, resulting in poor air flow and power loss.

Shining 3D recently worked with a car mod manufacturer on designing an optimized exhaust pipe to be additively manufactured in metal. The exhaust pipe consists of three parts: the connecting rod, the gas heave and the exhaust. Shining 3D provided the entire solution, from design to final production.

In the early stage of the project, Shining 3D’s designers created the customized 3D model using professional design software Rhino. During the process, the internal structure of the exhaust pipe was optimized specifically for 3D printing technology, greatly increasing operation efficiency while reducing its volume.

After completing the design, the exhaust pipe was prototyped using Shining 3D’s professional SLA technology. This enabled testing and improved visual communication with the customer for additional product improvement.

After the design was approved by the customer, Shining 3D turned to distributed 3D printing. By assigning separate print orders to nationwide service centers such as Weihai, Haimen and Chongqing, several EP-M250 metal 3D printers were used in different service centers to print simultaneously, thus further reducing the time required for delivery of the final part.

Highlights:

1.More powerful acoustic wave 
Through the optimization of the structural design, the 3D printed exhaust pipe is more powerful and actually sounds like a supercar.

2.Weight saving
The weight of the 3D printed exhaust system was reduced by about 67%. Though the weight has been decreased, the intensity could fully meet the requirements without sacrificing aesthetics.

3.Guaranteed power
When the automobile is running at a high speed, if the back pressure exhaust pipe cannot emit the exhaust gas, it will affect the power output of the engine. The 3D printed exhaust system has good diversion rate. According to different outgassing speed of the car engine, it can arrange exhaust gas trends efficiently through its unique air channels. This ensures optimized engine power output under different working conditions.

4.A Model of 3D E-printing
It is worth mentioning that in this project, Shining 3D used the form of distributed 3D printing, fully utilizing idle time of equipment located in Weihai, Chongqing, Haimen and other service centers. It not only increased the utilization rate of the equipment, but also shortened the time of delivery.

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