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Formnext 22 Case
Studies

5-in-1 Manifold

Motorsport / Automotive

The challenge is to improve both the performance of the primary manifolds and the collector. In addition to streamlining the different gas flows into the exhaust to limit pressure losses, we must adjust the lengths and bending radii of each of the primary manifolds.

Heat Exchanger

Aerospace

PrintSky has associated both expertise of AddUp and Sogéclair to increase the Technology Readiness Level (TRL) of a new generation heat exchanger. The heat exchanger is designed to be installed in an air stream on a rack placed on a helicopter.

ADS Spherical Tank

Aerospace

The challenge is to improve both the performance of the primary manifolds and the collector. In addition to streamlining the different gas flows into the exhaust to limit pressure losses, we must adjust the lengths and bending radii of each of the primary manifolds.

Aurora Liquid Engine

Aerospace

The challenge is to improve both the performance of the primary manifolds and the collector. In addition to streamlining the different gas flows into the exhaust to limit pressure losses, we must adjust the lengths and bending radii of each of the primary manifolds.

Cold Plate

Space/Automotive/Aeronautics

With the trend towards electrification of transportation systems comes the issue of cooling the numerous electronic components. The challenge is twofold because the onboard mass must also be as low as possible.

Flight Command

Aerospace/Off Road Vehicles/ Aeronautics

This Multi-Axis Controller Handle is specially designed for the piloting of vehicles (turrets, drones, lifting equipment, etc.) bringing improved ergonomics for a wide range of applications.

HEWAM Heat Exchanger

Aeronautics

Heat Exchanger With Additive Manufacturing or HEWAM is a project aiming to develop a heat exchanger using all the potential of additive manufacturing in a geometry that fits with a wide range of surfaces and volume used in aerospace industry.

Hydraulic Block

Aerospace/Aeronautics/Automotive/Energy

The biggest challenge with this complex part is building the inner channels. Laser powder bed fusion can allow for optimized channels design, in order to decrease pressure drops and optimize flow inside the part.

Medical Implants

Medical

Thanks to advanced biocompatible materials available for use in additive manufacturing, more and more medical applications are benefiting from this technology.

Injection Mold

Tooling

Zahoransky needed a mold insert with eight bores with mold rings. The challenge was to improve the cooling of the inserts using additive technology in such a way that the cycle times and productivity of the molds would be significantly increased.

Rocket Nozzle

Aerospace

The complete development of an orbital launcher engine is a long and complex process requiring several iterations of design, manufacturing, and static firing tests. With the field of the micro and mini launchers becoming such a competitive environment, rapid iteration is both a technological and commercial necessity.

Copper Heating Coil

Energy

Schneider Electric redesigned an inductor to maximize its technical and industrial performance. This new inductor was impossible to manufacture using conventional processes, but additive manufacturing made it possible to overcome these manufacturing constraints.

Shoe Mold

Tooling

A large proportion of the world’s plastic products are now made using injection molding technology. However, the manufacture of molds can be extremely expensive, and time-consuming, and requires the use of several processes including machining. Fortunately, it is now possible to produce molds using metal 3D printing.

Siebenwurst Injection Mold

Tooling

Siebenwurst worked with AddUp on a WBA project and the challenge was to design the cooling system specifically according to AM suggestions. Then Siebenwurt should simulate the new metal part geometry for functionality using Thermo software.

Waveguide

Aerospace

Traditionally, this system is composed of several welded and assembled parts, which is a long and delicate industrial phase to complete. The objective of this study is to explore the numerous advantages and limitations of metal additive manufacturing in the realization of waveguide-based cavity filters.