In the competitive automotive industry, optimising fuel efficiency is crucial for reducing emissions and meeting regulatory standards.
Current post-processing techniques for additively manufactured automotive components are very often inadequate to contribute to the levels of engine performance and fuel efficiency demanded by today’s stringent regulatory requirements.
Holdson was approached by a prominent automotive OEM which manufactures a vital engine component from AlSi10Mg aluminium alloy using additive manufacturing (AM) techniques. The as-printed surface of the part exhibited a roughness of approximately 6.6 μm Ra, with semi-sintered powder particles adhering to the surface. This unevenness was leading to issues with fuel flow, hindering the component’s performance. The customer had already tried mechanical post-processing techniques to smooth the part, but these methods were inconsistent, time-intensive, and ultimately unable to achieve the desired level of refinement.
electroform™ was able to polish the AlSi10Mg engine component without abrasive mechanical processes or harsh chemicals. In this case, the technology effectively removed the semi-sintered powder and smoothed the surface, eliminating friction points that would otherwise disrupt fuel flow. The process achieved the required surface finish in a 25-minute cycle time. This represented a 2/3 reduction in cycle time compared to the post-processing methods previously employed by the customer, meeting their demand for processing efficiency without compromising quality. electroform™ successfully reduced the surface roughness of the customer’s AlSi10Mg engine component from an initial 6.6µm Ra to a polished finish of 2.2µm Ra, to meet the specified quality standards.
To read more, and see the before and after results, please download the case study.
