Design of a ferrous alloy manifold in additive manufacturing –European Union-funded project
The project aims to promote sustainability in the automotive and aerospace sectors through the prototyping in additive manufacturing of a component of the suction system of CNC machines. The goal is to improve energy efficiency and reduce environmental impact, making production processes more sustainable.
Financed by the European Union - NextGenerationEU (National Sustainable Mobility Center CN00000023, Italian Ministry of University and Research Decree n. 1033 -17/06/2022, Spoke 11 -Innovative Materials & Lightweighting). The opinions expressed are those of the authors only and should not be considered as representative of the European Union or the European Commission’s official position. Neither the European Union nor the European Commission can be held responsible for them.
CLAM-E2 Project – Innovation and Sustainability in Additive Manufacturing
Goal achieved: thanks to advanced Computational Fluid Dynamics (CFD) analysis, the redesigned manifold eliminated stagnation zones and improved flow dynamics, achieving a 25% reduction in dynamic pressure drop.
Cutting-edge technology: using Laser Powder Bed Fusion (LPBF) 3D printing in AISI 316L stainless steel, we were able to create geometries that are nearly impossible to obtain with traditional manufacturing methods, fully leveraging the potential of Design for Additive Manufacturing (DfAM).
Field validation: tests on the metal prototype confirmed an increase in inlet flow velocity, ensuring more efficient aspiration compared to commercial components, and reducing powder dispersion during operation.
Sustainability: the project integrated cost and environmental impact analyses, optimizing materials and minimizing waste. Through an optimized design, we achieved an 87% reduction in production waste.