Uncategorized

The StreetScooter C16: Make Way for a New 3D Printed Car at EuroMold

At EuroMold next week, attendees are going to get a glimpse of a completely different sort of 3D printed car.  Though the chassis is not printed all in one piece, like the Strati from Local Motors, all of the exterior plastic parts and a number of interior components of the StreetScooter C16 were 3D printed by Stratasys 3D printers.

c16 3D printed car from streetscooter stratasys

Developed out of the Production of Engineering of E-Mobility Components (PEM) of Aachen University, the StreetScooter C16 is an electric production vehicle with a price tag of under €10,000.  The program spun out the StreetScooter company in 2010, which sought to create an electric car that could compete with fossil fuel driven vehicles in terms of price, performance, and safety, while being more ecologically sustainable.  With a weight of 450kg (1000lbs), without the battery, the StreetScooter C16 has a range of 100 km (80 miles) and can reach speeds up to 100km/h (60mph).  In this way, the C16 is perfect for city driving.  To produce the short range vehicle, funding was provided by university professors and German auto suppliers and experts from more than 80 companies, including 3D printer manufacturer, Stratasys.

objet 3D printer for 3D printed car c16 streetscooterAll of the exterior plastic parts of the C16 were 3D printed in Digital ABS on the Objet1000, Stratasys’ large-scale, multi-material printer.  The Objet1000’s build volume of 1000 x 800 x 500mm (39.3 x 31.4 x 19.5in) allowed designers to produce parts up to a meter in length and, according to the company, resulted in the fabrication of the car’s “large front and back panels, door panels, bumper systems, side skirts, wheel arches, lamp masks, and a few interior components such as the retainer instrument board and a host of smaller components.”

Aachen University Professor of Production Management in the Faculty of Mechanical Engineering, Achim Kampker, said of the printing technology’s role in the project, “The Objet1000 is the largest multi-material 3D Production System on the market and Aachen University was the first university in the world to have one. Being able to use it in the development of large and small parts for StreetScooter was exciting in itself, but the contribution the 3D printed parts made to the construction of the car was enormous. The ability to produce full-scale prototypes that perform like the final parts, accelerated testing and design verification, enabling us to bring to market a prototype electric car in just 12 months – something that is just unimaginable with traditional manufacturing.”

3D printed part for c16 streetscooter at euromold

In fact, Aachen University has been using 3D printing even before StreetScooter was formed as a company.  In the early design phases of the vehicle, the geometrical and functional prototypes of the vehicles were printed, from the instrument board to the mirror compartment, mode switch panel, and Deutsche Post bonnet logo.  The final production model of the car was developed for Deutsche Post AG, which now uses a delivery van version at work in Germany.

The 3D printing process, however, doesn’t stop at design and prototyping.  The technology will be used to fabricate custom vehicles for StreetScooter customers. Prof. Kampler continues, “With the advanced multi-material 3D printing technology available to us from Stratasys, vehicles can be easily customized for specific customers, enabling us to design on-the-fly. These cars can be developed from scratch and ready in a matter of months, not years, as with traditional automotive production processes. The StreetScooter project has demonstrated to us how a whole new approach to car design and manufacturing is possible with 3D printing.”

Director of Global Education at Stratasys, Shelly Linor, adds, “The StreetScooter is the latest example of Stratasys’ leadership in additive manufacturing for automotive design and production. With StreetScooter, the Objet1000 3D Production System not only enabled the very rapid design and development of the vehicle, but also demonstrates the capabilities of additive manufacturing for producing final parts used in demanding applications.”

I’m a bit jealous that 3DPI’s Rachel and Davide will get to see it up close next week at EuroMold. I had my eyes on the Fiat 500e, but this C16 is looking pretty good! I wonder if they export to the US…