The introduction of Additive Manufacturing (AM), specifically the Laser Powder Bed Fusion (LPBF) process, effectively addressed these challenges with the goals of:
- reducing production time and industrial costs,
- optimizing the component’s weight,
- enhancing overall thermal and functional performances.
In the initial phase, the original geometry (designed for casting production) was produced via additive manufacturing to ensure production continuity. This was followed by redesign iterations aimed at fully leveraging AM's capabilities, introducing innovative design solutions.
The results achieved are significant:
- 57% weight reduction compared to the original component,
- 48% reduction in time and cost compared to the first printed version,
- 60% reduction in time and cost compared to the cast version.
Beyond production benefits, the project introduced complex thermal geometries unattainable with conventional manufacturing methods, enabling more efficient cooling of the prechamber and contributing to increased system reliability and efficiency.
This project represents a strategic proof of concept for adopting Additive Manufacturing on critical components of internal combustion engines, with direct impacts on overall efficiency and the transition toward a new generation of high-performance green engines.
Speakers:
Matteo Mameli, Quality & Performance Improvement Expert - AM, FINCANTIERI
Vincenzo Fiore, Design Engineer, Isotta Fraschini Motori - Fincantieri Group