Palm Springs, CA — ProMetal RCT, LLC, an Ex One Company, has become the latest Technology Partner in the DiMora Motorcar program to develop the $2 million Natalia SLS 2 sport luxury sedan. An integrated product and process team will use the ProMetal digital 3D printing technology to produce castings for the 1200-horsepower Volcano V16 engine without the need for patterns or tooling.
Rapid Casting Technology (RCT) is a generative or additive process. The ProMetal RCT equipment automatically builds sand molds and cores for casting metal directly from CAD data. Standard foundry industry materials are used, enabling easy integration of the new equipment into existing manufacturing and foundry procedures. The large building volume and high building rate combine to make patternless production a reality for metal-based prototype castings and low volume production. The molds and cores are built in an additive layer-wise fashion using a printhead, analogous to the ink-jet technology commonly used in desktop printers.
According to Dan Maas, Director of Business Development for ProMetal,
“This revolutionary ProMetal RCT process allows design freedoms,
heretofore never available to the casting designer or the foundry.
Removing the requirements for parting lines, draft angles and providing
undercuts is just the tip of the iceberg,” asserted Maas. “Providing
nested cores, spiral vents, volute shapes, integration of multiple
components, in-situ cores, and unique rigging geometry to minimize
turbulence are design features that are being utilized today by
advanced companies.”
Ex One Vice President Dr. Howard Kuhn has
noted that today’s high-technology workforce is well prepared to take
advantage of the capabilities made available through digital
manufacturing. “The modern generation’s love affair with digital
products positions them for a comfortable transition to, and
enthusiastic attraction toward, digital work in manufacturing–through
both virtual simulations and exciting production tools, such as
ProMetal’s Rapid Casting Technology.”
“The stringent
specifications of the DiMora Volcano V16 engine give us an excellent
opportunity to demonstrate what RCT allows the engine designer and
manufacturer to accomplish,” said Maas. “There is no room for error
when building an exotic, lightweight aluminum engine that produces 1200
horsepower.”
DiMora Motorcar Founder Alfred DiMora pointed out
the advantages that most impressed him about the ProMetal process.
“This technology is at the forefront of digital additive manufacturing
for the production of complex 3D shapes. During the design process,
being able to accomplish in a few hours what used to take days allows
you to refine your design through additional iterations. Eliminating
patterns and tooling saves time and reduces waste, making the entire
process faster, cheaper, and greener, while producing a final product
that is superior in every way. The Volcano V16 will be an unmatched
engine thanks to the engineering skills and technology of ProMetal RCT.”
MPF
