3D Printing of a Functional Oil Pan for a Plastic Automotive Engine

Overview

Polimotor LLC, a company experimenting with polymers to build engines has consulted with us to create a fully functional plastic oil pan using a 3D printing process. When creating the oil pan we are to focus on improving the interlaminar shear strength and prevent any deformities of the oil pan. The team is also to conduct material testing and machine testing before prototyping and eventually, printing a final functional oil pan.

Objectives

The objective of this project is to select the best machine and material for printing, then adjust the previous design, fabricate, and test a 3D printed oil pan that will be a functional component of a plastic engine. During the course of the project, the objectives did change as the team was unable to use the intended material with the 3D printer. As a result, the team focused on optimizing printer parameters with a material that was compatible with the 3D printer.

Approach

– Consulted sponsor on which methods of manufacturing the oil pan has been printed with previously

– Adjusted the Solidworks model given to us to make it 3D printing and manufacturing friendly

– Used a slicing software to look at potential support structure and printing options

– Conducted Material Testing (DSC and TGA) to help determine optimal printing settings

– Changed material from using Ultem 2310 to Arnite due to concerns with the Ultem and the machine (JuggerBot) that we were using at CIMP-3D

– Tensile testing was completed to find the strongest speed and heat chamber settings

– Compared these test results with given values for Arnite

– Used a Cost Analysis to compare printing with pellets and filament, along with using different printers

– Created test pieces with a printer that had varying geometry to help determine optimal printing parameters

Outcomes

– Created a calculation method for optimal extrusion rate

– Found slicer software methods to achieve clean prints

– Solved issues related to under extrusion and warping

– Conducted tensile tests to observe layer adhesion strength

– Tested material characterization of PEI 2310 for potential future use

– Final printer settings:
– Temps: 295°C Nozzle, 95°C Bed, 60°C Chamber​
– Speeds: 3000-6000 mm/min​
– Layers: 45°/135° alternating orientation