Additive manufacturing and three-dimensional (3D) printing solutions company Q.BIG 3D is transforming the way in which large-volume automotive components are manufactured using its QUEEN1 3D extrusion printing system, making it economically viable and beneficial for automotive industry players.

The company uses a variable fused granulate fabrication (VFGF) process, which includes the use of a variable nozzle that enables fast printing with a processing speed of about 500 mm/s, and high material throughputs guaranteed for geometric form and in-fill area jobs – referred to as ‘turbo mode’ – as well as low material throughputs for high-precision in the ‘detail mode’.

The detail mode of the variable nozzle is mainly used for fine structures or textures and fastening elements. In contrast, the turbo mode allows for enhanced speed for rapid build times during the manufacturing of large-volume automotive components.

Additionally, the QUEEN1 3D system, in tandem with the variable nozzle and VFGF process, applies the material layer by layer – much like primitive additive manufacturing or 3D printing – maintaining a combination of 1.5 mm in detail mode and 3 mm in turbo mode.

The benefits that accompany Q.BIG 3D’s product and service offerings are ample for automotive industry players and original-equipment manufacturers. Firstly, unlike traditional mould-based manufacturing processes, 3D extrusion printing of automotive parts does not come with high tool costs. This, in turn, makes it highly cost-effective, as manufacturers will not have to spend money on tools for single large-volume components.

“In a tool-based moulding process, the tool costs massively limit profitability. In 3D printing, we overcome these limits by combining a variable nozzle with a large build space,” says Q.BIG 3D founder Dennis Herman.

He adds that material cost procurement is the main benefit of 3D granulate printers, as this process does not require filaments, which are usually necessities in mould-based parts construction.

Some of the projects completed using the QUEEN1 3D printing system include model components for caravan construction; assembly and measuring jigs for automotive application; and a full-size helicopter cockpit.

These are indicative of the futuristic nature of 3D printing of fully functional automotive components for an array of transportation modes.

“We are producing the future. 3D material extrusion using the VFGF process is pushing the boundaries of what is possible and is making a whole new level of cost-effectiveness and amortisation possible.

“I see enormous potential for product development in large-format 3D printing. This also applies to lightweight construction, bionics and saving resources. Above all, however, the VFGF process is an accelerator for the Industry 4.0 approach,” enthuses Herman.