3D Printed Exhaust Pipe Applied on Ford Mustang

Metal 3D Printing in Direct Manufacturing

Background

For most commuters, the daily driving commute is changeless. To make it less boring, some car owners pursing the individuation style which lead to the idea that modify their cars lawfully, such as having the auto exhaust pipe customized.

Due to the limitation of conventional soldering technology, traditional exhaust pipe manufacturing faces the problem of too simple design of air flow, complex design is hard to implement. For the current market, the gas flow form of auto exhaust pipe is mainly planned bygraphic design, resulting in problems like poor air flow and power loss.

The auto exhaust pipe for Ford Mustang completed by traditional technology and design

The auto exhaust pipe for Ford Mustang completed by traditional technology and design

Metal 3D Printing in Direct Manufacturing

Recently, Eplus3D has successfully customized a 3D printed auto exhaust pipe for a car modification manufacturer, and now the exhaust pipe has been used in a Ford Mustang car for assembly trial.

The exhaust pipe consists of three parts, the connecting rod, gas heave and exhause. Eplus3D provides the entire solution across from design to final production.

In the early stage of the project, Eplus3D’s designer designed the customized 3D model in the professional design software Rhino. During the design process, the designer designed the internal structure of exhaust pipe optimized by 3D printing technology, greatly increasing the operation efficiency and reducing its volume.

Exhaust pipe 3D data

· Exhaust pipe 3D data

After completing the design, the designer printed out the exhaust pipe by 3D printing SLA technology to test and used it in visually communication with the customer for further product improvement.

Left: SLA 3D printed model for design confirmation and assembling test

Right: The internal structure of exhaust pipe optimized by 3D printing technology is very difficult to process by traditional technology

After the design was confirmed by the customer, Eplus3D used the form of distributed 3D printing. By assigning separate print orders to nationwide service centers such as Weihai, Haimen Chongqing and etc., mental 3D printers EP-M260 in different service centers could print simultaneously, which greatly shortened the time of delivery.

Exhaust Pipe

Summary

1.More powerful acoustic wave

Through the optimization of the structural design, the 3D printing exhaust pipe is more powerful and sounds like a supercar.

2.Weight saving

The 3D printing exhaust system has reduced the weight by about 67%. Though the weight has been decreased, the intensity could fully meet the requirements and the exhaust system also looks nice.

3.Power Guarantee

When the automobile is running at a high speed, if the back pressure exhaust pipe cannot emit the exhaust gas, it will affect the power output of the engine. The 3D printing exhaust system has a pretty good diversion rate. According to different outgassing speed of the car engine, it can arrange exhaust gas trends reasonably by its unique air channels, which ensures the power of engine under different working conditions.

It is worth mentioning that in this project, Eplus3D used the form of distributed 3D printing, fully utilizing idle time of equipment located in Weihai, Chongqing, Haimen and other service centers. It not only increased the utilization rate of these equipment, but also shortened the time of delivery.