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Case-studies 

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AURORA LIQUID ENGINE

AddUp has chosen to support the Estaca (Higher School of Aeronautics and Automotive Engineering) in the additive manufacturing of a regenerative cycle space engine, in inconel 718. This project, called “Aurora Liquid Engine“, is being carried out in partnership with engineers from ArianeGroup and Air Liquide, and its objective is to demonstrate the relevance of PBF technology (Laser Powder Bed Fusion) for the aerospace sector.

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HEAT EXCHANGER

Metal additive manufacturing is relevant for thermal equipment. It allows to create channels with complex shapes, thus improving thermal performance while reducing the volume. This heat exchanger has thin walls (250 µm) and double curvature channels that are impossible to produce by conventional techniques.

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CAMERA SUPPORT

Metal3D“ is a mission commissioned by ESA (European Space Agency) as an technology demonstrator. Its objective is to characterise the mechanical properties of a material shaped in microgravity. To carry out this experiment, two batches of test specimens are being produced by the same printer design. While the first batch will be produced in Toulouse in terrestrial gravity, the second will be built in space, more precisely in the Columbus module of the ISS (International Space Station), in microgravity.

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ORNMENT (DS-LOUVRE)

As part of a partnership with the prestigious Louvre Museum (Paris – France), DS Automobile wanted to develop its DS line by producing a limited edition car, the “DS7 CROSSBACK – Louvre Edition“. This prestigious car is a product marked by innovation and art, DS Automobile has decided to use metal additive manufacturing to produce parts with complex designs, in close collaboration with AddUp, and its FormUp 350 machine.

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COLD PLATE

In the race for electrification, among the issues is the cooling of electronic components. The challenge is twofold because the weight of the vehicle must also be as low as possible. Currently, the cold plates are made with two half aluminum alloy shells enclosing a curved copper alloy tube. The result is a heavy design with loss of heat transfer between the half shells and the tube, with a risk of loss of waterproofing.

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PROTOTYPE MOLD

In the shoe industry, molds for the Direct Injecting Process are used in higher-end manufacturing. Direct injection is primarily used to bond the sole of a shoe to
the upper, without the need for adhesives. The uppers positioned and a molten material (normally a polymer) is forced into the mold cavity. During this process, the sole attaches to the upper in a single operation.

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MEDICAL PARTS

Optimize the design for a medical implant using a lattice structure to improve osseointegration and improve overall design making it ideal for additive manufacturing.

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PISTON – MOTORSPORT

Reduce the of mass of a piston head to compensate for the use of high density material and improved cooling.

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STATIC MIXER

The static mixer is a complex part to produce in traditional manufacturing with many parts welded together with a high risk of leakage.
The part consists of 72 rising and falling vanes in 4 blocks and 2 orientations at 90°. The fins are located in a regulated tube for better thermal homogeneity.

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INJECTION MOLD

In the tooling industry, and especially for injection molds, short injection times are crucial for economic efficiency. These decide how many injection molding machines and molds you need and what the final part price will be.

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HYDRAULIC MANIFOLD

Weight reduction is getting more and more important in aeronautics for economical and environmental reasons. In the meantime, the market is eager for innovation and rise of performances. Using powder-bed fusion technology (L-PBF) to obtain a part with low weight and high mechanical characteristics.
Designed by Safran, the part is 253 mm high, printed on a FormUp®350 machine with medium powder TA6V 5-25 μm, in the context of the SOFIA project.

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BURNER NOZZLE

  • Approach to catalog a new generation of burners
  • Willingness to innovate and reduce lead times
  • About 50 burners per furnace
  • Scrap rate for this part is very high
  • Supply is difficult in machining and brazing
  • Control and adjust the penetration length inside
    the refractory brick
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COPPER PARTS

The geometry of inductors is becoming increasingly complex and has reached the limit in traditional manufacturing. Additive manufacturing provides ease of production of complex parts and short lead times.

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FGM CUBES – DED

Functionnaly Gradient Materials (FGM) Cube 30 x 30 x 30 + 50 mixing level

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MILL SERVICE

In the mill industry, cutting dies are inserted into a mill in several segments.
Due to the permanent and continuous cutting process, the edges of the cutting contours are subjected to wear that keeps coming. This leads to increased production costs and downtime for repair and replacement of the segments. In addition, corrosive media and acids stress the cutting contours from corrosive Steel.

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MALETTE

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