HRE3D+ | The WORLDS FIRST 3D-Printed Titanium Wheel
11-13-2018, 12:16 PM
#1
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HRE3D+ | The WORLDS FIRST 3D-Printed Titanium Wheel
HRE WHEELS PARTNERS WITH GE ADDITIVE TO CREATE FIRST 3D-PRINTED TITANIUM WHEEL
HRE and GE Additive’s AddWorks team have used Electron Beam Melting (EBM) technology to create a new prototype wheel made from an advanced titanium powder, unveiling the first automotive wheel to be made with this process.
Vista, Calif. (November, 2018) – HRE Wheels and GE Additive announced a partnership agreement today and unveiled the first titanium wheel created using EBM technology (a type of 3D printing). Known as “HRE3D+”, this new prototype wheel shows what the future of wheel technology will bring and how advanced materials like titanium can be harnessed to create complex designs.
The goal of the “HRE3D+” project was to test the capabilities of additive manufacturing in a practical application and to create a highly-sophisticated wheel design with an elusive material like titanium. With a traditional aluminum Monoblok wheel, 80% of material is removed from a 100-pound forged block of
aluminum to create the final product. With additive manufacturing, only 5% of the material is removed and recycled, making the process far more efficient. Titanium also has a much higher specific strength than aluminum and is corrosion resistant, allowing it to be extremely lightweight and to be shown in its raw finish.
There was an intensive design collaboration between the Vista, California based team at HRE and the GE AddWorks team out of Ohio. Using design queues from two existing models of HRE wheels, the two companies worked together to create a stunning example of what is possible with additive manufacturing.
The wheel was produced on two Arcam EBM machines - Q20 and a Q10 in five separate sections,, then combined using a custom center section and titanium fasteners.
"This is an incredibly exciting and important project for us as we get a glimpse into what the future of wheel design holds,” said HRE President Alan Peltier. “Working with GE Additive’s AddWorks team gave us access to the latest additive technology and an amazing team of engineers, allowing us to push the boundaries of wheel design beyond anything possible with current methods. To HRE, this partnership with GE Additive moves us into the future.”
“HRE prides itself on its commitment to excellence and superior quality in the marketplace. It was a natural fit for AddWorks to work on this project with them and really revolutionize the way wheels can be designed and manufactured,” said Robert Hanet, senior design engineer, GE Additive AddWorks
EBM Printing: Electron Beam Melting is an additive technology that uses and electron beam to melt and fuse fine layers of titanium powder into a solid. These fine layers are built up one at a time to create the full design.
Titanium Powder Bed: The additive design is built up in a bed of fine titanium powder which results in very little wasted material, unlike traditional subtractive methods like machining from a solid forging.
Powder Recovery: The excess titanium powder is removed to reveal the final design and recycled for future parts.
Support Removal: Temporary internal support structures are printed along with the part to provide support to the structure and to facilitate extremely complex designs. These are removed by hand and recycled after printing.
Post Machining: Mating surfaces and threads were CNC machined post-printing to ensure tight tolerances of assembly. Compared to traditional machining from forgings, this post-processing is minimal.
Hand Finishing: The tops of the spokes were hand brushed to create a beautiful decorative finish. Because Titanium has excellent corrosion resistance, no additional powder-coat or clear-coat was necessary.
Cleaning: Due to the minimal machining and finishing, cleaning is a simple process simply to remove any oils or remaining powder.
Assembly: All the parts were hand-assembled into a carbon-fiber rim barrel using titanium fasteners.
The “HRE3D+” wheel will be on display from November 13-16 on GE Additive’s booth (D30) at the form next tradeshow in Frankfurt, Germany. For more information on HRE Wheels, visit https://www.hrewheels.com/wheels/concepts/hre3d
About HRE Performance Wheels:
HRE designs, engineers and manufactures 3-piece and 1-piece forged aluminum alloy wheels for Racing, Performance & Luxury cars and SUVs in their San Diego, California-based, TÜV-approved facility. HRE’s built-to-order wheel sets offer a customized choice of offsets, widths and finishes, resulting in a uniquely personal style and performance solution for each customer’s application. HRE wheels are sold through select high-end car dealerships, specialty retailers and performance companies worldwide. For more information, visit www.hrewheels.com or call an HRE wheel expert at (760) 598-1960.
About GE Additive:
GE Additive – part of GE (NYSE: GE) is a world leader in additive design and manufacturing, a pioneering process that has the power and potential to transform businesses. Through our integrated offering of AddWorks additive experts, advanced machines and quality materials, we empower our customers to build innovative new products. Products that solve manufacturing challenges, improve business outcomes and help change the world for the better. GE Additive includes additive machine providers Concept Laser and Arcam EBM; along with additive material provider AP&C. EBM machines create dimensionally accurate parts quickly and efficiently by using a high-power electron beam for high melting capacity and productivity. The EBM process takes place in vacuum and at high temperature, resulting in stress-relieved components with material properties better than cast and comparable to wrought material.
11-13-2018, 01:00 PM
#3
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This is pretty fascinating, but it's unclear to me what kind of implications this technology has on these four parameters, relative to traditional forged aluminum wheels:
1. Weight
2. Stiffness
3. Strength and Longevity (fatigue)
4. Cost
Would love to hear some comparison estimates - thanks!
1. Weight
2. Stiffness
3. Strength and Longevity (fatigue)
4. Cost
Would love to hear some comparison estimates - thanks!
11-13-2018, 01:11 PM
#4
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Better have PCCB's behind those bad boys or you'll NEVER get the brake dust out!
11-13-2018, 02:39 PM
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On a serious note - I am curious to address the basic questions noted above: This manufacturing process as it relates to weight/strength/durability compared to current forged wheel technology. Or does the process allow for great amount of intricacy?
Amazing application of additive manufacturing. I am scared to ask with regard to cost.
- Chris.
11-13-2018, 04:44 PM
#7
One day some high school kid is going to be printing these in his basement - with a design competition sourced from global participants - with automated stress testing and data analysis collected from other designs. That's where this is headed.
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11-13-2018, 04:48 PM
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11-13-2018, 05:10 PM
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However in watching the video HRE notes the point of this exercise was to provide the possibilities of what additive manufacturing can achieve over current forge milling processes.
Clearly this wheel is intended to showcase the technology.
Very cool stuff.
GE kept talking about cost. I have to assume the actual process is relatively inexpensive to "print" using titanium dust; the capex requirement to purchase the machines and software - that's a different story. I would assume that it would end up being really expensive on the end-user once you start to amortize those costs out across your cost of goods. Expensive wheel for sure. Super cool!
Better put wheel locks on those puppies. How much, approx per wheel?
11-13-2018, 05:50 PM
#11
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I don't think anyone would steal them.
11-13-2018, 05:53 PM
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11-13-2018, 07:56 PM
#14
Former Vendor
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Thank you for all your comments! These particular wheels though, are not for sale. This is proof of concept to push the industry in a new direction, we have no plans to take this particular wheel to production. We're looking to innovate what the wheels in the next generation will be by pushing the boundaries of technology today. To satisfy those inquiring about durability, the strength and stiffness more than meet our standards, but we aren't looking to publish any specific details. Weight is low but could be significantly lower if we were to take an actual product to market.
Love the responses though, thank you!
Love the responses though, thank you!
