3D Printed Car Spoiler Components

The EDAG Group's OptiAMix research project the "WING3D" focuses on a new concept for a rear wing system that enables active aerodynamics through 3D printing. Design engineers realised that the rear wings produced using conventional methods did not offer the option of integrating a hydraulic system into their mount, therefore it was vital to look at al The interaction of different materials, such as aluminium and tribologically optimised iglidur® plastic, offers the system an innovative mode of operation in the adjustment of the rear wing with simultaneously increased abrasion resistance.

Key success: High time savings, reduced costs, highly complex component structure can be produced in a single piece.

With 3D printing, it is possible to design and print each individual component in such a way that it is both fully functional and visually appealing. At the same time, a wide variety of materials can be used, enabling customised printing of the lightweight components. By using 3D-printed plain bearings made of iglidur® i3, a tribologically optimised igus® plastic, the rear wing system can be operated with significantly less friction and maintenance-free than with a normal plastic. Compared to conventional materials for laser sintering, the high-performance polymer has up to 30 times better abrasion resistance and is the perfect material for adjusting the rear wing. In contrast to manufacturing processes such as milling or injection moulding, the complex inner areas of the component could be implemented quickly and easily in a single piece using 3D printing.

3D-printed plain bearings were used for the rear wing system. The great advantage of the process is the rapid printing of the highly complex components, which cannot be manufactured as easily using conventional manufacturing processes. The special shape and the complicated interior can be produced in just one piece using additive manufacturing. This reduces costs and ensures efficient production. In the active rear wing system in particular, it is important to enable low-friction adjustment. igus® developed iglidur® i3 plastic for 3D printing manufacturing to produce plain bearings that are both wear-resistant and low-friction. The self-lubricating components are also maintenance-free and therefore ideally suited for the actively adjustable rear wing.

A bionic aluminium holder for the rear wing with integrated hydraulics was produced. This is realised by the movement of a piston using oil pressure of up to 90 bar, which enables the angle of attack to be adjusted continuously from 6° to 42°. With the help of an electric cable built into the bracket for the sensor to determine the position or angle of the wing, it actively adapts to the driving situation. A braking function is also provided, which is supplemented by an integrated LED brake light in the holder. In addition, 3D-printed plain bearings were used to reduce friction. All components created using additive manufacturing are precisely adapted to the respective other components without having to sacrifice function or visual aesthetics - a true interaction of form and function that is raised to a new design level through 3D printing.