Porsche Classic delivers classic parts from the 3D printer
The Porsche Classic range comprises around 52,000 parts. If a certain spare part is no longer in stock or if the stock runs out, it is remanufactured with the original tools. For larger quantities, production with new tools is also possible. However, the supply of spare parts, which are only in demand in very limited quantities, poses a greater challenge to Porsche’s Classic experts. Remanufacturing of small quantities with new tools would usually be uneconomical.
Porsche Classic evaluates different manufacturing processes before implementing a component project. The continuously increasing quality of the additive manufacturing processes with a tendency to lower costs offers an economical alternative for the production of small quantities. For example, for the release lever for the clutch of the Porsche 959, which is no longer available. The component made of grey cast iron is subject to very high quality requirements, but is rarely needed – not least because of the small production number of the super sports car with only 292 units. Only selective laser melting could be considered as a suitable and cost-effective manufacturing process.
For the release lever, powdered tool steel is applied to a machining plate in a computer-controlled layer less than 0.1 millimeter thick. An energy-rich light beam melts the powder at the desired points under an inert gas atmosphere to form a steel layer. This creates the complete three-dimensional component layer by layer. The printed release lever performs both the pressure test with a load of just under three tons and the subsequent tomographic examination for internal defects with flying colors. The practical tests with installation in a test vehicle and extensive driving tests also confirm the flawless quality and function.
Based on the consistently positive experience, Porsche is currently producing eight additional parts in 3D printing. These are steel and light metal parts made with the help of selective laser melting and plastic components made by SLS printers. SLS stands for selective laser sintering, in which the material is heated to just below the melting point and the residual energy is applied by a laser to selectively melt the plastic powder at this point. All parts are subject to at least the quality requirements of the original production period and generally meet even higher standards. Dimensional accuracy and accuracy of fit are ensured by installation tests. Plastic parts made from different materials, as in the original, must be resistant to oils, fuels, acids and light, depending on the area of application.
Porsche Classic is currently testing a further 20 components to determine whether 3D printing is suitable for their production. The advantages: three-dimensional design data or a 3D scan of the component are sufficient as a starting point for production. If required, the components can be produced on demand, thus eliminating tooling and storage costs. All parts produced in the 3D printing process meet the technical and optical requirements for maximum authenticity, Porsche assures.
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