C.L.I.P. Printed Performance Intake Manifold
imgur.com/a/nIB2d
imgur.comPosted Mar 30, 2017, 3:31 PM UTC
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imgur.comThat's a pretty misleading company name, but that looks sweet.
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If you're not familiar with the Carbon 3D printers, they're really amazing. They print upside-down in a resin, like a typical resin printer, but they use a semi-permeable membrane to slightly delay the formation of the hardened plastic. They then use a DLP projector to get the entire layer in one go, and smoothly raise the platform as they print. The combination of the DLP and the delayed curing means they end up with an isotropic material, can print crazy stuff like elastomers, and can print insanely fast.
TED talk on it: https://www.ted.com/talks/joe_desimone_what_if_3d_printing_was_25x_faster
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This is a work of art!
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Thank you!
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Just showed out intake team, what was the total cost for this?
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Well, licensing the printer is about $300,000 per year (Source). So I can't imagine it was cheap.
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It was likely sponsored. Many other teams use filament based 3D printing to make intakes for less cost though.
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Interesting! One of the vendors we are working with has suggested a carbon 3d printed option. It's nice to see the kind of results that can be had.
What motor is this going on?
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We are impressed with the results. This is going on a CBR 600RR.
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You said the internal spike decreased turbulence. Was that running a transient analysis or a steady state? And did decrease in turbulence lead to an increase of mass flow?
I feel like the spike would interfere with the intake runner length tuning. Did y'all take that into account. That said, I do like that spike idea...
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This is not my area so I couldn't say. I will ask our intake lead and get back to you.
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How are you holding down your fuel rail/injectors? Hope it's not just the plastic.
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Hope it's not just the plastic.
We sure are. What is your concern?
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We had a 3D printed intake and we had an incident where the thing broke along the print lines, spraying fuel all over a hot engine with a driver in the seat. We don't like to advertise that fact, but we also don't want it to happen to other teams, so you might want to reinforce it with a bracket if at all possible.
(The epoxy's from an earlier attempt to cut down on vacuum leaks, not fix it, heh)
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The reason we went with Carbon3D is the CLIP technology, where there is actually no "print lines" like a traditional FDM printed part. Instead, the printing process results in a fully isotropic material when finished. Thank you for the input, though. That couldn't have been a fun experience!
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What material is that? It doesn't look lasered to me. I made one that was laser sintered out of nylon gf-12 and mounted the fuel rail on it just fine. The direction you have the part oriented when you print it also effects it's strength.
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It's Ultem. We've had our printed intakes for a few years, and this just recently broke, so with a bit of consideration in design (and maybe a SLA/SLS printer) it can work. But we've suspended using 3D printed plastic on any safety-critical bits.
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Sweet looking design and great surface finish. I remember talking with Carbon 3D at the IMTS show in Chicago, and their printing process is petty unique.
I'd be interested to see how the CLIP parts hold up to temperature cycles and UV exposure as compared to conventional photopolymer printed parts.
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In a few years new FSAE kids will never know the blood, sweat tears and cursing that went into building a monocoque.
Or anything for that matter. Some kid joined this year thinking he was hot shit with CAD and 3D printers, and lost his shit when we told him to fab something out of aluminum.
Or welding a tube frame chassis. My buddy is in the architecture masters program and they have several 7axis robots they can use to cut, bend, and weld steel tube. According to him it's possible to build our entire chassis with the 2 big 7axis robots the architecture school has.
Yeah but how many teams have the money to make use of that sort of tech.
If they weren't already on campus and we had to go to an outside company to do it we couldn't. But it's a resource we have on campus which would make it affordable. Not something we'd ever do but the fact that the technology exists to do it is cool and that's more what my post was about.