The Role of 3D Printing in Active Aerodynamic Designs

• What was needed: An active rear spoiler system
• Manufacturing method: Selective laser sintering with laser sintering powder
• Requirements: Complex component, low coefficients of friction, low weight, reduced design time and costs
• Material: iglidur I3
• Industry: Automotive
• Success through collaboration: Great time savings, reduced costs, highly complex component structure can be produced in one piece

The application at a glance:
The "WING3D" concept from the OptiAMix research project is a rear spoiler system that uses 3D printing to achieve active aerodynamics. One of the problems with rear spoilers manufactured with conventional methods is that there was no way of integrating hydraulics into the mount. The interplay of various materials, such as aluminium and tribologically optimised iglidur plastic, provides the system with an innovative functionality for adjusting the spoiler while increasing abrasion resistance.
 

Highly complex plain bearings made of iglidur I3 make a low-friction and maintenance-free operation possible (copyright: EDAG Engineering GmbH)

Problem

The EDAG Group's OptiAMix research project with igus GmbH was aimed at building an adjustable rear spoiler that changes position based on the car's situational driving dynamics. Active spoiler adjustment requires wear-resistant components with a low coefficient of friction. A robust material was needed so that there would still be enough room for integrated hydraulics. With the conventional manufacturing processes, the implementation of the highly complex lightweight components required for this was hardly feasible, as the planning and production of these components are too time-consuming and costly.

Solution

But 3D printing allows each part to be designed and printed so that it is both fully functional and visually attractive. At the same time, a wide variety of materials can be used, allowing customised lightweight component printing. By using plain bearings printed in 3D from iglidur I3, a tribologically optimised igus polymer, the rear wing system can be operated with significantly less friction and maintenance than with normal plastic. The high-performance polymer has up to 30 times the abrasion resistance of conventional laser sintering materials and is the perfect material for adjusting the spoiler. In contrast to production methods such as milling or injection moulding, it was possible to realise the complex interior of the part via 3D printing easily and quickly - in one piece.

Maintenance-free 3D printed plain bearing inserts

3D printed plain bearings have revolutionized the rear spoiler systems in vehicles. The key benefit of this technology is the rapid production of complex components that would be challenging to create with traditional manufacturing methods. Additive manufacturing allows for the creation of intricate shapes and internal structures in a single piece, which streamlines production and cuts costs. This is particularly advantageous for active spoiler systems, where the ability to adjust with minimal friction is crucial. igus GmbH, a company headquartered in Cologne, leverages 3D printing to convert the specially designed polymer iglidur I3 into durable, low-friction plain bearings. These bearings are not only wear-resistant but also self-lubricating, eliminating the need for maintenance and making them perfect for the precise adjustments required in active rear-wing systems.

A low-friction adjustment to the driving situation is no problem with plain bearings from iglidur I3.

High design requirements with full functionality

A bionic aluminium mount was manufactured for the spoiler and its integrated hydraulics. The latter achieves up to 90 bar of oil pressure from piston movement, allowing stepless angle adjustment from 6° to 42°. An electric cable for the position and angle-detection sensor is installed in the mount, enabling the spoiler to actively adjust to the driving situation. A braking function is also provided for, complemented by an LED brake light in the mount. 3D printed plain bearings were also used to reduce friction. All components for which additive manufacturing was used are adapted precisely to the other components without compromising function or aesthetics – a fantastic interplay of form and function that moves 3D printing to a new level of design.

An attractive design and high functionality are possible thanks to 3D printing. (Copyright: EDAG Engineering GmbH)

iglidur I3: Active system without sacrifices

Iglidur I3 is a material engineered specifically for the demands of laser sintering processes. It boasts an abrasion resistance that surpasses traditional laser sintering materials by up to 30 times. The integration of solid lubricants within the polymer matrix enhances the sliding capabilities of parts, significantly extending their operational lifespan across various applications. This high-performance polymer is the ideal choice for active systems requiring a harmonious blend of design and functionality. Moreover, the self-lubricating components produced through the additive manufacturing process facilitate a frictionless, maintenance-free operation at critical points, such as the bearings of a spoiler. This attribute contributes to a level of system longevity unattainable with conventional plastics.

iglidur I3 SLS powder