2023-06-26 06:30:18
Launched by Renault Group in 2020 at the Flins plant, the ReFactory program aims to develop new activities linked to the circular economy of mobility. Additive manufacturing is one of these new activities.
The program ReFactory launched by Renault Group wants to make the Flins factory a circular economy factory dedicated to mobility. An evolution consistent with the ecological ambitions of the diamond brand, which wants to achieve carbon neutrality on all its industrial sites by 2040.
Younesse Khalil, Manager of the 3D printing center at the ReFactory in Flins, explained to Engineering Technics how the Refactory program should allow Renault to develop circular economy projects, through 4 activities: the extension of the lifespan of vehicles, the production and storage of green energies, the optimization of resource management, and innovations that are more widely accessible. It is in extending the lifespan of vehicles that additive manufacturing plays a major role.
Engineering techniques: The Flins site has additive manufacturing tools. What is their use, for which part of the project do we use 3D printing?
Younesse Khalil: The Flins site is open to the various Renault Group entities, external customers and companies, and especially those wishing to print parts via the 3Dexperience platform. The additive manufacturing tools available in Flins can be used in several project stages.
On the preliminary project phase, for example for the printing of prototype parts that will be used to validate the geometry of the vehicle, the mountability on the vehicle, or even the design.
During the project, certain parts of the vehicle manufactured in plastic injection require several modifications before the final validation, and to avoid expenses on the modifications of the molds, the various small series of test parts are manufactured in 3D printing, until the final validation. . Then, we launch plastic injection manufacturing. This type of part can also be a part added to the vehicle, not originally planned, and which solves a quality problem. This makes it possible to be reactive to satisfy customers while waiting for the manufacture of the injection mold.
For example, the Flins 3D printing service has been manufacturing a locking clip for the Trafic handle for a year, while waiting for the injection mold.
Finally, on everything concerning the post-project phase, we work with the following-sales service for the printing of several different parts (serial parts or accessories).
What materials will be used for 3D printing? For what reasons ?
In fused wire deposition printing, we use different types of plastics: PLA, ABS, TPU, ASA, ULTEM, PETG…
In powder sintering printing, we use Nylon PA12 powder (Flins is the only site that has the HP 5210c machine that prints with non-CMR certified products).
These materials are consumed for different uses, depending on their properties. For example, ULTEM is a material used for a switch control for an external customer, because it meets railway standards and withstands a temperature of 173°C.
Nylon PA12 is used in most aspect parts because it is easy to tint or paint and very strong (an aspect part of the Alpine A110R is made in Flins with this material).
Finally, TPU, which has flexibility properties and is generally used in 3D parts used to protect clamping, riveting and assembly tools on vehicles to prevent damage.
What is the main advantage of 3D printing?
The most obvious advantage is in terms of saving time and cost of producing parts.
Will the use of additive manufacturing in the maintenance of old vehicles and the manufacturing of new vehicles become widespread in the years to come?
Yes indeed, many projects are underway on customizable vehicle accessories and 3D series parts.
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