Caracol, a worldwide chief in superior robotic applied sciences, has produced a full-size sports activities automobile roof utilizing its Heron additive manufacturing robotic platform, eliminating the necessity for conventional molds and chopping lead time by a claimed 40% in comparison with typical strategies.
The part, which weighs 66lb (30kg), was printed in 27 hours utilizing acrylonitrile butadiene styrene strengthened with 20% carbon fiber (ABS + 20% CF), extruded via a 5-millimeter nozzle on Heron AM’s HV extruder.
The ensuing construction is monolithic, with no joints or meeting steps, integrating ribs, trimming reference options, and localized reinforcements instantly inside the print.
Hybrid post-processing targets automotive floor requirements
Following printing, the part underwent trimming and floor preparation utilizing options pre-designed into the LFAM part. A fiberglass hand layup was utilized to the inside floor to compensate for anisotropy inherent in layer-based manufacturing and enhance load-bearing efficiency.
Materials compatibility and adhesion have been validated via mechanical testing to substantiate resin and filler choice, and subsequent bodywork, coating, and sprucing phases introduced the near-net-shape half to an automotive-grade floor end appropriate for end-use purposes.
Mechanical efficiency targets akin to conventional sheet steel options have been achieved via the hybrid AM course of, which mixed polymer and composite applied sciences.
Turkey’s LFAM Heart gives manufacturing infrastructure
The mission was carried out on the LFAM Heart in Turkey — a manufacturing hub operated by Başaran, Omniform, and Otostech utilizing Caracol’s expertise — and was developed in collaboration with ES Garaj.
The middle operates on a microfactory mannequin supporting distributed, on-demand manufacturing near the purpose of use, with a completely digital workflow from CAD file to completed half.