In order to fully demonstrate the potential of additive and subtractive manufacturing in electric vehicles and reveal the changes in shape, material and performance of products brought about by 3D printing, 3D Science Valley has teamed up with China 3D Printing Culture Museum. AME 2018(Additive Manufacturing Excellence)3D Printing Forum series focusing on new energy vehicles will be held in Shanghai on 1st June 2018 jointly with Fraunhofer Research Institute, Gasse Automotive China Research Institute and experts from domestic and foreign automotive additive manufacturing field.

DKSH is one of the speakers at this forum. For this reason, Mr. Hu Jinhong, General Manager of DKSH Engineering business, is invited to share with us how DKSH provides turnkey solutions for new energy vehicles.

-- Huge market potential

Car market is one of the world's largest consumer goods market, now the new energy vehicles will bring the huge consumer market upside down, according to the analysis of the university of aachen, Germany, in 2010 accounted for 98% of global market diesel locomotive, hybrid 2%, in 2020, the world will produce 103 million passenger vehicles, including diesel locomotive for 81.9 million, The market share was 79.5%, and the number of new energy vehicles (including hybrid and electric vehicles) was 21.1 million, accounting for 20.5%, among which the pure electric vehicles were 4.1 million.

By 2030, the world is expected to produce 120 million passenger vehicles, of which internal combustion engine vehicles account for 9.6 million, accounting for 8% of the market share, new energy vehicles (including hybrid, electric) for 110.4 million, accounting for 92%, of which the pure electric vehicles are 50.4 million. Going from 2% market share to 92% market share in 20 years is a hell of a change! In China, due to energy conservation and emission reduction and policy promotion, the market reaction speed of new energy vehicles will be much faster than the international market.

- Customized production and higher precision challenges

At the same time of the leapfrog development of new energy vehicles, the demand for customized production and higher production and manufacturing technology requirements will pose a great challenge to traditional manufacturing technology.

Due to the upgrading of consumption market, the car market more and more customized orders demand, using the Toyota and ford assembly line produced cars are difficult to achieve customer critical custom specification, 3 d printing can easily achieve high flexibility and high complexity of the production, so in personalized new energy cars, 3 d printing will have a broad space for development.

Take the new energy vehicle powertrain (motor and gear) industry as an example, the gear used in the traditional fuel automobile gearbox can not meet the requirements of electric vehicle powertrain. The maximum engine speed of conventional fuel vehicles is 8000r/min, while the maximum motor speed of electric vehicles can reach 28000r/min. The shift from relatively low speed to ultra-high speed puts particular demands on precision and surface roughness in the powertrain.

Image credit: DKSH

At the same time, without the traditional fuel engine roar as a mask, the transmission noise is particularly harsh. Improving gear precision and reducing transmission noise is a problem that the electric vehicle industry must face. The process of traditional automobile powertrain has been difficult to meet the higher precision requirements of electric vehicle gearbox for gear. Therefore, how to transform the functional design of gear into technological design and perfect processing has become a difficult problem faced by practitioners in the gear industry.

DKSH innovative manufacturing solutions for new energy vehicles

New energy vehicles are the future development direction of the country and the automobile industry, which requires more efficient motors, longer battery life, higher energy efficiency ratio of air conditioning, these demands bring great challenges to our traditional automobile manufacturing industry.

Image credit: DKSH

DKSH is a high-tech company listed in Switzerland. Since 1923, it has introduced European and American equipment into the Chinese market. At present, DKSH owns the exclusive sales rights of more than ten European and American high-end brands in China. We can achieve from model to product in 3-5 days through innovative 3D printing mold technology, and can also achieve flexible and efficient production of key parts of new energy vehicles through innovative processes, fixtures, cutters and automated design of the whole line. Provide strong support for enterprise transformation and innovation!

-- From 3D printing to intelligent manufacturing -- a full set of solutions for high-performance motors

DKSH can provide a full range of motor solutions from casting development to mass production. Through rapid prototyping technology based on 3D printing, we can provide customers with as fast as 3 days from concept to casting. Through flexible special aircraft, customers can achieve up to one million pieces of high-performance pre-assembly motor production. We are more focused on high performance automation production in harsh environment after motor assembly.

Image credit: DKSH

Rapid casting Motor delivery based on 3D Printing: Through the process analysis and rapid response of professional 3D printing services, DKSH can provide customized rapid development services for customers who only need to provide a 3D model of the motor, We can provide customers with 3d printing based rapid prototyping mold process in the shortest time (1/10 of the time of traditional mold technology), to help customers establish casting supply from research and development to small batch production of motor.

Image credit: DKSH

Before assembly machine batch production: because of the high precision and rapid cooling water jacket design, high performance motor is a typical thin-wall before assembly, high precision spare parts, the problem of machining the market, DKSH through the analysis of the technology professional, special cutter, fixture, can provide customers with 2 to 8 workbench, using robot automatic up-down material, Help customers to achieve the annual production of 100,000 to one million pieces of high-performance motor housing.

Image credit: DKSH

Assembled motor intelligent manufacturing units: in order to realize high speed and low noise, high performance motor generally after fulfilling the main assembly for final precision machining, has been completed at this time due to the motor assembly of main components, the motor will be completed in the case of very demanding precision machining, on-line detection and directly, and then complete the final motor assembly. This posed great challenges to the supplier's understanding of motor structure, the design of special processes, and the automatic solution. DKSH successfully achieved this almost impossible task in the motor industry.

图片来源：DKSH