The need
Discontinued parts, broken supply chains and technological obsolescence often make mechanical spare parts difficult or impossible to obtain. The “Mechanical Obsolescence Management” research project is developing CAx-based manufacturing processes to provide spare parts economically and on demand.
Our approach
The approach combines digital design and simulation tools with modern manufacturing technologies. The focus is on additive processes, in particular metallic 3D printing, which enable flexible and tool-free production. In addition, electrochemical processes are used for targeted surface treatment to optimize wear resistance, dimensional accuracy and surface quality.
Demonstrator
Practical implementation is based on the replication, optimization and additive manufacturing of a cylinder head for a 6-cylinder diesel engine. The component is being tested at the Scientific-Technical Center for Engine and Machine Research (WTZ) as part of the prototype production of a hydrogen engine. Additive manufacturing allows geometry, cooling channel routing, material distribution and structural strength to be adapted—opening up new applications and increasing performance and service life.
At a glance
CAx‑based process chain (design & simulation)
Additive manufacturing: metal 3D printing
Electrochemical surface treatment
Demonstrator: cylinder head (6-cylinder)
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