Additive Manufacturing
so for a company like PWR , unlocking that potential is increasingly valuable in a competitive field like motorsport .
Solution Based on Velo3D ’ s success in the space industry ( and a host of other factors ), PWR concluded that Velo3D would make an ideal AM partner in the development of their heat exchangers . What PWR was struck by first was Velo3D ’ s performance capabilities regarding heat exchanger production . In 2019 , PWR conducted an evaluation of various printing technologies . Velo3D printed heat exchangers featuring 320um leak-tight walls and 220um turbulators that resulted in a 33 percent lower pressure drop vs the competition . Pressure tested to 6 bar at PWR ’ s world class testing facilities , this water / oil heat exchanger features some of the thinnest leak-tight walls on a metal AM heat exchanger ever printed . This heat exchanger exceeded expectations outperforming devices printed on other manufacturing platforms , which led PWR to purchase its first Velo3D Sapphire metal 3D printer . What cemented the relationship was the performance of the dedicated service team when the first system was delivered . Being new to metal AM , the PWR team required guidance in implementation . It also didn ’ t help that PWR invested in the Velo3D endto-end system as lockdowns saddled operations throughout Australia . However , through email and remote communication , and with the assistance of a dedicated field-based engineer , the Velo3D team proved “ invaluable ” as the PWR team learned the technology . After a collaborative design phase , PWR was able to begin printing on their Velo3D Sapphire printer . “ Seeing an additively manufactured part on the Velo3D machine was a big shock — a very good shock ,” says Torven Taylour , Design Engineer at PWR . “ Okay , this is now what ’ s possible . How can we leverage this machine to further our products and offer our customers something they couldn ’ t have had previously ?” Throughout the process of test printing , PWR leveraged the Velo3D system ’ s ability to print incomparably thin walls and low inclination angles without supports to achieve designs that cannot be feasibly produced by neither traditional manufacturing nor alternative metal additive manufacturing systems . Due to the specifications of their clients , however , PWR began by 3D printing more complex housings in aluminum combined with traditionally manufactured cores to produce exceptionally high-performance products . Because PWR uses aluminum for printing — a relatively uncommon material in metal AM compared to more conventional materials such as titanium and inconel — they had to further lean on the team from Velo3D to optimize their printing process to compensate for the material . This consultation and collaboration also included the Velo3D team providing guidance and advice on heat treatments for metal AM-produced parts .
Results PWR has had multiple successful prints of heat exchanger housings which are then combined with traditionally manufactured cores marrying the advantages provided by both additive and traditional manufacturing . To be spatially efficient and to provide adequate distribution of fluids , some heat exchanger housings require complex geometries that are difficult to achieve with traditional manufacturing processes . Instead , PWR additively manufacture their housings on their Velo3D Sapphire printer . The solution ’ s low inclination and support-free capabilities allow them to manufacture housings with built-in tubes and complex internal fluid galleries that would be difficult to achieve with alternative additive manufacturing methods . Based on this success , the company is further developing heat exchangers that are entirely 3D-printed on the Velo3D system . The prospect of the technology has become a major selling point for their motorsport clients , particularly Formula One racing teams . “ We have involvement with every Formula One team ,” says Taylour . “ Not all Formula One teams leverage additive manufacturing from us , but the teams that do , focus on the Velo3D solution . They are confident in what it produces .” The closed loop , tightly controlled environment of the Sapphire printer has made it an ideal system for printing in aluminum . Having an automated printing process has reduced labor costs and lead times for finished parts and provided a consistency and reliability of results that has been attractive to high-end customers . Furthermore , this automation has reduced the team ’ s exposure to hazardous chemicals endemic to conventional AM solutions and reduced waste of the expensive aluminum powder . Because of the level of control available with the Velo3D system , PWR is now exploring off-the-shelf , scalable heat exchanger production to provide cooling solutions for a broader base of customers rather than the bespoke , small batch manufacturing runs that have been successfully adopted in competitive motorsport . The company ’ s success in AM is also bringing in new industries of clients , including aerospace . The partnership between PWR and Velo3D is a true success story of technological capability meeting a dedication to service . Through collaboration with Velo3D , PWR is now able to offer high-performance additive manufactured heat exchangers to their highprofile clients , while reducing labor costs and health risks .
About the company
Velo3D provides a fully integrated metal 3D printing solution for mission-critical parts in the space , automotive , semiconductor , and energy industries . Unlike conventional metal 3D printing solutions or traditional manufacturing methods , Velo3D helps design engineers build the complex parts they need without compromising their design or part quality .
18 Heat Exchanger World April 2023 www . heat-exchanger-world . com