Scope Of Application

Prototyping and printing master models for small-scale production of carbon fiber parts for luxury cars. Create a lightweight master model for small-scale production of carbon fiber parts using a heat-resistant and durable material.

The master prints are printed from engineering material, which is based on ABS with carbon fiber for less material shrinkage, greater strength, stiffness and heat resistance, and a smoother finish.

Production of parts of any shape, even with complex geometry. A good milling machine costs several times more than a 3D printer. Post-processing of parts after printing is also easier than after milling, it includes coating with a liquid primer and varnish.

The detail development process includes the following steps:
1. 3D scanning;
2. 3D modeling;
3. 3D printing;
4. Validation of the master model;
5. Post-processing of the master model (liquid putty and varnish);
6. Manufacturing of composite tooling;
7. Making a carbon fiber part.

Creation of parts of an electric motorcycle that can be used in the final product or as a prototype for further production using other technologies.

Mostly various composite plastics (both carbon- and glass-filled) were used, as well as ABS and PLA. Battery cell mounts, dashboard holders, battery protection panels, aerodynamic fairings and more have been printed.

3D printing is often a less expensive and more convenient method of production: equipping a part of a room for 3D printing is much easier than organizing production using other technologies. Also in this case, 3D printing is economically justified: since we are talking about piece parts and a small series, printing is much more profitable than, for example, vacuum molding or plastic injection.

The production of single non-standard parts in some cases is more rational using 3D printing technology. The use of composite plastics makes it possible to produce functional parts - fasteners, protective covers. Manufacturing the same elements from other materials using casting technology can be very expensive, and the use of turning and milling machines will entail a large loss of material.

Prototyping and printing of the cold air intake system for the Audi S8. Creation of complex geometric shapes from a material with lower heat capacity and thermal conductivity than traditional ones.

First, a 3D model of the car was obtained using 3D scanning to determine the dimensions and relative positions of all the necessary components for the positional design of the cooling system and air intake, after which the engineering team developed the pipe and intercooler. Prototypes of the resulting models were printed from PLA for verification after optimization.

Printing allowed the use of materials with lower heat capacity and thermal conductivity than aluminum, which is traditionally used for the manufacture of such pipes. The 3D-printing faithfully reproduces the engineer's intent.

Printers allow you to work with a wide range of engineering materials, and their combination covers such tasks as high loads, high temperatures, gasoline and oil resistance. In addition, the technology of manual bending of sheet metal does not allow for high accuracy of the geometry of the product, and therefore such a product does not work optimally. Printers always give high accuracy, and the size of the working field allows you not to limit customers in their developments and there is no need to divide parts into parts.

The client has set a task of creating an air filter box for the Dodge RAM. A special feature was to make the part as similar as possible to the original factory version, but to improve its characteristics.

It was decided to create an air filter from composite ABS instead of sheet aluminum. For this kind of challenge, the Picaso Designer XL PRO is perfect. So, after just 120 hours of printing, the team received a finished high-quality detail.

The team was able to create a working prototype in a week. Developing such products in the traditional way would be much more expensive and time-consuming. 3D printing and Picaso 3D technologies allows you to achieve these fine results.