Laser melting produces lightweight car components

The Functional Lattices for Automotive Components (FLAC) project aims to reduce the weight of automotive components by 40-80%.

Engineers at the University of Nottingham are developing lightweight automotive components using selective laser melting. 

The process uses a three-dimensional computer-aided design to digitally reproduce each part in a number of layers. Each layer is then 3D-printed using lasers, by melting sections of a bed of aluminium alloy powder. The melted layers fuse and solidify to create structures, which can be assembled to form a complex lattice, creating a very lightweight component. 

The Functional Lattices for Automotive Components (FLAC) project aims to reduce the weight of automotive components by 40-80%, while optimising thermo-mechanical performance. The process also minimises waste because only the necessary materials are incorporated into the components and any aluminium powder waste is easily recyclable. The selective laser melting process requires no special tools or hazardous cutting fluids, resulting in environmental advantages.

Professor Chris Tuck, FLAC project leader at the university’s Additive Manufacturing and 3D Printing Research Group, said: “FLAC will benefit UK automotive companies, increasing their competitiveness by allowing them to adopt innovative routes for the design and manufacture of lightweight componentry, with shorter lead times and lower costs than are presently available.”

The three-year project, which secured £368,286 from Innovate UK, will investigate components such as brake calipers, heat sinks for LED headlights and powertrain sub-systems. 

The university believes that in the short term these components, which will deliver decreases in vehicle carbon dioxide emissions, will be taken up in the luxury car and motorsport markets.