After we hear about 3D printing lenses for optical functions, it’s typically for eyewear. However a gaggle of researchers from Tunghai College in Taiwan are trying into the expertise for a unique use case: headlight lenses. Their paper, revealed within the Optica Publishing Group journal Utilized Optics, evaluates and compares headlight lenses produced with additive manufacturing to these made utilizing extra conventional manufacturing strategies, like reverse engineering and CNC machining. The staff stories that AM has a number of benefits over these different processes in relation to fabricating headlight lenses, comparable to improved efficiency and adaptability.
As one of many first industries to provide speedy prototypes, the “automotive market is without doubt one of the longest-standing customers of 3D printing expertise,” in accordance with a report by Additive Manufacturing Analysis. The report additionally states that a number of market, environmental, and technological tendencies are combining to rework the automotive trade, with many turning to 3D printing “as a essential instrument to allow this transformation, from the transition to electrical automobiles (EVs) to the drive in the direction of making provide chains extra sustainable.” Not too long ago, we’ve seen examples of AM getting used to make headlight tabs for auto restore, so why not 3D print the lenses as nicely, if the potential is there?
3D printed headlight tabs
“Conventional manufacturing strategies include limitations comparable to excessive prices, lengthy supply occasions, and low yield,” defined Chia-Hung Yeh, Examine Crew Chief and a professor at Tunghai College. “This examine makes use of a headlight lens as a case examine to discover the potential of 3D printing as an alternative choice to conventional manufacturing strategies, aiming to create a quicker product verification course of for the trade.”
Changing the normal mass manufacturing mannequin, decision-makers within the optical plastics trade are actually focusing extra on addressing particular buyer wants. Conventional lens molds are pretty costly, which suggests producers must fastidiously weight the advantages towards the monetary dangers. This will result in a for much longer deliberation course of earlier than manufacturing even will get began. Moreover, in accordance with Yeh, mould manufacturing can turn into extra intricate whenever you’re coping with advanced product designs, which additionally slows issues down.
“To remain aggressive in a quickly altering market, manufacturing design capabilities should meet these calls for rapidly,” he defined.
On this examine, the researchers in contrast 3D printing with CNC machining and reverse engineering, which have historically been used to fabricate optical parts.
“3D-printing expertise holds vital promise for producing optical parts by permitting speedy prototyping of product designs, enabling designers and engineers to rapidly validate the aesthetic, structural, and purposeful elements of their creations,” stated Wei-Min Chen, a doctoral pupil at Tunghai College. “Moreover, it makes it attainable to deliver intricate and progressive designs to life, shortening the event cycle for brand spanking new car fashions and boosting general market competitiveness.”
The analysis, led by PI Chia-Hung Yeh (left) and doctoral candidate Wei-Min Chen (proper), was performed on the Digital Design Engineering Laboratory, Division of Industrial Engineering and Enterprise Info, Tunghai College. Credit score: Chia-Hung Yeh, Tunghai College
The researchers used a headlight lens as their case examine. They used a reasonably cheap resin materials to 3D print 14 lenses in a single 8-hour print cycle, which signifies that the expertise can enhance operational effectivity, help one-off prototype design manufacturing, and velocity up manufacturing for small-batch manufacturing of various designs.
In evaluating the manufacturing outcomes of their 3D printed headlight lenses, the staff additionally discovered that the expertise gives wonderful floor high quality and precision. The researchers analyzed a number of essential elements of the lenses, comparable to floor profile and roughness, peak and diameter, mild transmittance, and radius of curvature. They reported a minimal curvature radius error, and a 93% transmittance, which exceeds that of a commercially accessible polycarbonate (PC) lens with a 90% transmittance. The 3D printed lenses have been comparable, although not higher, than CNC machined ones with a 94% transmittance and reverse engineered samples with 91% and 94% transmittance. Lastly, they decided that the 3D printed headlight lenses have been less expensive than historically manufactured variations.
A brand new examine demonstrated the advantages of 3D printing for manufacturing, utilizing a headlight lens for example. 3D printing achieved distinctive precision and floor high quality whereas additionally outperforming conventional strategies in manufacturing effectivity and cost-effectiveness. The picture exhibits the Luce Memorial Chapel in Taichung, Taiwan, seen by means of one of many 3D printed headlight lenses. Picture Credit score: Chia-Hung Yeh, Tunghai College
“3D printing gives key benefits, comparable to consolidating a number of parts right into a single construction, lowering manufacturing prices, and simplifying meeting,” Yeh concluded. “Total, 3D printing in optical functions improves design flexibility, value effectivity, and sustainability, positioning it as a transformative power within the trade as expertise continues to advance.”
To asses the efficiency of 3D printed headlight lenses in additional sensible settings, the researchers now plan to look into explicit headlamp module mixtures and consider the interior components, like structural design, fixture temperature, and operational surroundings.
At our Additive Manufacturing Methods (AMS) final week in New York Metropolis, there have been a number of panel discussions and displays specializing in themes which might be associated to this analysis, comparable to “The Polymer Toolbelt,” and a session centered on Transportation, with talks together with “AM for Mobility” and “Combine to Scale – How Additive Manufacturing Works for the BMW Group.”
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