Additive Manufacturing of Automotive Prototypes Using Soluble Resin

This technical report outlines the method of producing automotive components using the Freeform method (FIM) and soluble resin for additive manufacturing. The process involves simulating the injection of high-strength poly(ether ether ketone) (PEEK) into molds created via 3D printing. The report assesses the surface condition of the finished product and discusses the advantages of using 3D printing technology in the automotive industry, particularly for creating complex geometries that traditional manufacturing methods cannot achieve. It highlights the challenges of producing individual parts, especially in the context of repairs, where traditional metal molds are economically unfeasible. The report details the materials used, including the specific resin and its properties, and presents findings from simulations conducted using Autodesk Moldflow software to compare the injection processes in metal versus resin molds. The results indicate that while resin molds may increase cycle times due to lower thermal conductivity, they allow for effective prototyping without the constraints of conventional metal mold production.