Toyota Console Box

Toyota Console Box


Toyota Motor Corporation (Toyota) wanted to launch the "LQ", a concept vehicle that leverages advanced technology to build an emotional bond between car and driver, at the Tokyo Motor Show. A new approach was required for the interior and exterior design. The center console was designed as an innovative free-standing object with a knob style shift lever and a touchpad which represented a major challenge. Additive design and manufacturing technology offered the best solution in terms of weight, design freedom, and reliability.

Toyota Outer Mirror Bracket

As the Toyota LQ has an electric drive system with batteries, Toyota engineers were challenged to reduce the weight of each component and achieve aerodynamic efficiency with a very innovative exterior design. The outer mirror was identified as an opportunity to apply additive design and manufacturing. Additive design and manufacturing technology offered the best solution in terms of weight and aerodynamics for the mirror stay. It also led to a reduction in sound emission. The result was a reduction of the number of individual parts as well as of weight and sound emissions, and an overall exciting and new look of the mirror.
Toyota Outer Mirror Bracket
Individual Elbow Implant

Individual Elbow Implant

Unfortunate situations may easily occur in which people get seriously injured and will, therefore, need a medical implant. Especially in the area of joints such as the elbow, this means a big challenge. Quite often, standard implants do not provide a satisfactory result. In the worst case, there is no suitable solution at all and the joint must be stiffened which will deteriorate the patient's life quality dramatically. A customized solution with a reliable production technology is needed to overcome these difficulties and to enable the serial production of individual implants. The design is intended to facilitate the bone ingrowth as well as the entire healing process.

Individual Transtibial Orthesis

Patients who need an orthesis still have to be satisfied with standard solutions and sizes. However, an improperly fitting orthesis is unfavorable in many ways, as it hinders, rubs, pushes, causing additional pain and at the same time slowing down the healing process. Therefore, in many cases, it's of great importance for the success of the therapy that the patient does not receive a prefabricated but customized orthesis. These ortheses are often very expensive and need a lot of time for manufacturing. A better solution with an alternative production technology is necessary to reduce all these disadvantages and to enable a customized serial production of these ortheses.
Individual Transtibial Orthesis
Thrust Reverser for Business Jet

Thrust Reverser for Business Jet

The thrust reverser for a business jet consists of 12 single cascades positioned around the turbine of the aircraft. These cascades are traditionally made from titanium by using investment casting. The problem: There is just one supplier on the market. High procurement costs, high dependence, long delivery times, and no options for product optimization are just a few of the disadvantages our customer is facing. An innovative solution is necessary to reduce all these difficulties by using an alternative technology for serial production.

Aluminum Star Tracker Bracket

An important part of a satellite is the so-called star tracker bracket which holds an optical device for controlling and steering the exact position of a satellite in orbit. Currently, such a bracket consists of more than 400 individual parts and has its own cooling circuit to prevent it from deformation by the heat of the sunbeams which would make the exact positioning of the satellite impossible. Due to these requirements, the component is heavy and complex. A weight reduction of 50 % and a functional integration of the cooling circuit is the declared aim of TAI. In this ongoing project, an innovative design and manufacturing solution for a new and better star tracker bracket are sought to guarantee a safe launch and reliable positioning of the satellite in orbit for many years.

Aluminum Star Tracker Bracket
Sand Dispenser

Sand Dispenser

The DB Group (Deutsche Bahn) is one of the world's leading mobility and logistics companies and employs some 331,600 people around the globe. The DB Group designs and operates the transport networks of the future. Through the integrated operation of traffic and railway infrastructure as well as the economically and ecologically intelligent connection of all modes of transport, the DB Group moves people and goods. When the manufacturer of the left-side sandbox housing - a part of the brake system - has ceased its production, Deutsche Bahn got into trouble because a failure of the sand dispenser leads directly to a downtime of the locomotive which immediately causes immense downtime costs. Since the original component was manufactured as grey cast iron, the purchasing department tried in vain to find alternative suppliers which made the sand dispenser a critical part.

Cable Holder

ARaymond constantly analyzes the market and works proactively with the customers to keep the finger on the pulse of emerging industry trends - from connected and driverless cars to stricter regulations across the globe - to innovate the solutions that car manufacturers are seeking today and down the road. ARaymond offers state-of-the-art fastening and assembly systems delivered just-in-time from 26 manufacturing plants in 25 countries worldwide. A fast but comparatively cheap solution was necessary to fulfill the customer's need for the injection molding of just a few prototypes for functional/material tests or small series with a lot size up to 20,000.


Cable Holder
Garniture Tongue

Garniture Tongue

The Hauni Group is the world's leading provider of technologies and technical services for the international tobacco industry. Hauni Maschinenbau GmbH, headquartered in Hamburg, Germany, is the leading company in the Hauni Group. For the production of cigarettes and filters, every manufacturing step is focused on maximum automation, outstanding quality, and excellent flexibility. Therefore, perfect production tools are needed. The garniture tongue, for example, is used in the manufacture of cigarette filters. It transports and shapes the filter material into a round and endless strand. This component is an important part.

Rocket Engine Fluid Manifold

Ariane 6, the latest rocket of the ArianeGroup, will be launched in 2020 and combines, as part of the RAMS (Reliability, Availability, Maintainability, and Safety) approach, proven solutions with innovation in order to address the changing needs of the market. A cost-effective and absolutely reliable solution is necessary for the serial manufacturing of the rocket engine fluid manifold in Ariane's Vulcain 2 rocket engine which is today a forged component. A cold fluid oxygen-methane gas mixture runs with high pressure through this manifold into the lower part of the combustion chamber which makes this manifold a very important part for the successful launch of the rocket.

Rocket Engine Fluid Manifold
Gear Lever and Taillights

Gear Lever and Taillights

Prototypes for design studies or functional tests are still a very important element of the product development process. Especially for FMCG or lifestyle products, a fast and reliable design validation is very important to reduce the time to market. Therefore, industrial designers and engineers are searching more and more intensely for new ways to validate their designs even quicker. But especially multi-colored and multi-material components are really challenging to be manufactured as a prototype. A new solution for the fast, realistic, and cost-effective manufacturing of design prototypes is necessary.

Bearing Housing

The Schaeffler Group is making a decisive contribution to “Mobility for Tomorrow“ already today with its high-precision components and systems in engine, transmission, and chassis applications, in addition to rolling and plain bearing solutions for a large number of industrial applications. For the distribution of a bearing casing, FAG Schaeffler planned the use of samples for the sales team. However, the large and heavy original casing was not suitable for a sample case. A practical solution was necessary to create a portable sample part for the sales process.
Bearing Housing
SCA - Selective Cement Activation

SCA - Selective Cement Activation

The construction industry has reached a turning point. The digitization of the construction industry is radically changing the complete interaction between designing, planning, building, and the collaboration of all actors. High construction costs, long construction times, extensive material consumption, and huge amounts of waste represent major challenges. At the same time, the need for more individualization and new solutions such as micro-apartments or tiny houses is increasing.  So, forward-looking solutions are sought to make construction faster, cheaper, more digital, more individualized, more sustainable, and more innovative in the future. That's why we are currently evaluating the possibilities for a completely new large-format additive manufacturing technology in the area of architecture and construction. SCA: Selective Cement Activation will arrive in 2020.

LPM - Layered Powder Metallurgy

In the automotive, aerospace, or defense industry, 3D printed metal parts become more and more important. But high costs, long production times, and part quality and reliability are still hurdles that need to be overcome. Most of the existing AM technologies are close to their maximum productivity level and can only improve gradually. A radically innovative solution is necessary to make a real breakthrough towards industrial additive manufacturing. With LPM, Layered Powder Metallurgy, we offer IP development partnership to interested companies so they can leverage this technology as early as possible to develop groundbreaking applications. A new industrial solution for cheaper, faster, and better additive manufacturing of complex metal parts with LPM is in development within a preferred partnership between Stratasys and FIT.
LPM - Layered Powder Metallurgy
Computational Engineering

Computational Engineering

Individualization is one of the current megatrends which results in a demand for more and more customized products, components, or equipment. Although additive manufacturing is a perfect solution for the production of small lot sizes, it doesn't solve the challenge of apportioning high development costs to a shrinking number of produced parts. Digitization and automatization are the key factors for a significant cost reduction in the field of product development. Especially computational engineering is a powerful tool to capture and digitize the function and properties of a product first on the basis of an algorithm. On the basis of digitized parameters, the product design will be created automatically - easy, fast, and cost-efficient. FIT started to evaluate appropriate software tools to create a solution for more efficient product development in the future.

SP3D - Supersonic 3D Deposition

The conventional casting of aluminum or copper blanks is often a lengthy and expensive affair, especially if just a few parts are required. This is especially true when it comes to copper which is very difficult to process by casting. A radically innovative solution is necessary for the fast, cost-efficient and quality-approved manufacturing of copper parts that are comparable to conventional casting. With Supersonic 3D Deposition  (SP3D), we are currently evaluating the possibilities of a super-fast metal additive manufacturing technology. To this goal, we offer IP development partnership to interested companies so that they can benefit from this technology as early as possible. The demonstrator is a copper heatsink.

SP3D - Supersonic 3D Deposition
Metal Coating

Metal Coating

For many applications, a part with a perfect surface yet low production costs is vital. A good example are parts for aerodynamic tests in a wind channel such as the shown brake thruster. An economic solution is necessary to optimize the properties of a part at low costs. Metal coating improves the mechanical and electrical properties of a component, increases the long-term dimensional stability, strength, and stiffness and ensures outstanding conductivity, a smooth surface, and appealing metal esthetics.

HPHT - High Pressure Heat Treatment

Safe, safer, safest – medical implants or other crucial end-use parts are subject to the highest quality requirements to avoid any kind of failure or risk during the lifetime of the component. Of course, well-established technologies like Electron Beam Melting (EBM) allow for a very high part quality with regard to density or porosity and produce absolutely safe parts. Various quality control technologies like CT scanning are used to prove the security level. But if you want to play really safe, High Pressure Heat Treatment (HPHT) will bring about the highest safety level - after all, nothing else counts for such ultimately important end-use parts like medical implants as this acetabulum implant.
HPHT - High Pressure Heat Treatment
Hirtisation

Hirtisation

Bone graters are single-use tools that are used for the preparation of the remaining bone material during implantation. These graters are disposed of right after surgery. Today, hip graters are already mass-customized because they are conventionally forged on demand for one particular patient. The required structure is finally hammered manually into the metal. This manufacturing process is complex, expensive, and lengthy - and somewhat archaic. A better solution is necessary to create customized hip graters with a perfect surface structure in a shorter time at lower costs.

Large advertising object for L'Oréal

For the commercial release of its new face cream of the „it“ product line (i.e. Innovative Technology), L'Oréal was looking for a very special way of presenting it at a press conference to attract attention and symbolize the innovative image of the "it" brand. The challenge: Time was relatively short to the inaugural press conference and no data model of the small original tube existed. Our specialists created a data model of the tube from scratch. After that, the object was built by using XXL 3D printing technology GDP (Gel Dispensing Printing) in three separate parts, which were assembled to form an impressively tall giant tube with a height of 1.80 m. Due to a refined finishing process, the GDP model was a perfect look-alike of the original – after only one week of production time.

Large advertising object for L'Oréal
Lightweight drone

Lightweight drone

The range of the UAV and the battery-powered flight duration are essential performance characteristics of remote-controlled aircraft. In order to massively increase the flight duration, our design specialists at FITNIK have developed the prototype of a special helicopter drone with an original length of 3.5 meters. The special feature of the drone's construction is its complex organic design which leads to a weight reduction of 80%. The structural load-bearing capacity is guaranteed. This means that the drone can fly almost twice as long as before.

Tool for customized facade

The eye-catching new boarding house on the AM campus of FIT Additive Manufacturing Group is the result of a close collaboration between the FIT product designers, architects Berschneider + Berschneider, and the Sto Group, a manufacturer and developer of lightweight construction systems. The facade stands out by a novel surface with a complex pattern of cavities which let the massive geometry of the matte dark appear delicate and weightless. Each of the mold inserts of the production panels was produced from aluminium by laser melting, which was considerably cheaper than milling them due to the complex faceted shape. The individual facade panels were pressed and demolded quickly and economically, fully integrated into the industrial process at STO. Thanks to the additive production, individualized house facades will hardly cost more than standard facades in a few years.

Tool for customized facade
Spare part of an air conditioner bracket

Spare part of an air conditioner bracket

For the mounting of air conditioning units, Faiveley Transport Leipzig GmbH & Co. KG, a subsidiary of the US-American Wabtec Corporation, uses conventionally manufactured clamps made of sheet metal. Availability as well as weight are becoming more and more important issues. That's why Wabtec searched for a weight-optimized variant of the 4.6 kg standard bracket. Topology-optimization and bionic design are the corner stones for the complete redesign of the original bracket. As the subsequent simulation showed, the new bracket is able to withstand the same loads as the conventional part. The main difference: the new bracket has only a weight of 0.8 kg, which means a weight reduction of 82 %! Since the new bracket is manufactured in one piece by additive manufacturing instead of being joined from 6 bent sheet metal parts, the assembly effort could also be noticeably reduced.

Serial production of anti-snoring mouthpiece

Around 3.7 m people alone in Germany suffer from obstructive sleep apnea (OSA). Oventus Medical, in cooperation with the Australian CSIRO, developed an individual mouthpiece that protects sleep apnea patients from fatal breathing pauses. As a specialist for the additive manufacturing of medical components, we provide reliable and certified processes for the production of titanium blanks for the medical products and devices industry. This enabled us to lead Oventus through an intensive prototyping and evaluation process, ending in true serial manufacturing, resulting in a run of 500 different components per week. In the course of this cooperation we developed the process for real series manufacturing of the titanium mouthpiece. The parts are manufactured with professional software tools and "Best in class" machines for the high quality production of medical implants according to DIN EN ISO 13485 as well as compliant to FDA requirements. A rigorous quality management system ensures the required quality standards (e.g. traceability etc.).

Serial production of anti-snoring mouthpiece

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