Ensuring the longevity of classic vehicles presents unique challenges, particularly when it comes to sourcing authentic spare parts. For marques like Porsche, with a rich heritage and dedicated following, maintaining a comprehensive inventory of components for their classic models is paramount. While Porsche Classic boasts an impressive catalog of around 52,000 parts, the production of extremely rare components needed in very small numbers poses a significant hurdle. Traditional manufacturing methods often prove inefficient and costly for such low-volume demands. However, a groundbreaking solution has emerged: additive manufacturing, more commonly known as 3D printing.
Additive Manufacturing: A Game Changer for Rare Car Components
When dealing with spare parts that are seldom required, the conventional approach of creating new tooling for small production runs becomes economically unviable. Porsche Classic meticulously evaluates various manufacturing processes before undertaking the reproduction of any component. Increasingly, additive manufacturing is proving to be a compelling alternative. The continuous advancements in 3D printing technology, coupled with decreasing costs, make it an economically sound option for producing small quantities of highly specialized parts.
Consider the example of the release lever for the clutch in the legendary Porsche 959. This grey cast iron component is subject to stringent quality standards, yet the demand is exceptionally low, reflecting the limited production run of only 292 Porsche 959 supercars. For such a part, selective laser melting stands out as the most viable manufacturing process.
The Selective Laser Melting Process Explained
The selective laser melting process is a marvel of modern engineering. It begins with the application of an ultra-thin layer, less than 0.1 millimeters thick, of powdery tool steel onto a processing plate within a computer-controlled environment. Inside an inert atmosphere, a high-energy laser beam precisely melts the powder at designated points, meticulously building up a steel layer. This process is repeated layer upon layer, gradually constructing the complete three-dimensional component. The 3D-printed release lever for the Porsche 959 underwent rigorous testing, including a pressure test with a load of nearly three tonnes and a tomographic examination for internal flaws. It passed both tests flawlessly. Furthermore, practical trials involving installation in a test vehicle and extensive driving assessments validated the component’s impeccable quality and functionality.
Expanding the Horizon: 3D Printing for Steel and Plastic Car Parts
Buoyed by consistently positive outcomes, Porsche is currently leveraging 3D printing to manufacture eight additional parts. These encompass both steel and alloy components produced through selective laser melting, and plastic parts fabricated using SLS (selective laser sintering) printers. SLS involves heating the plastic material to just below its melting point, with a laser then applying the remaining energy to fuse the plastic powder at specific locations.
Crucially, all 3D-printed parts adhere to, and often exceed, the stringent quality benchmarks of the original production era. Dimensional accuracy and fit are meticulously verified through installation tests. Depending on their intended application, plastic parts, mirroring their original counterparts, are engineered to withstand exposure to oils, fuels, acids, and light. Porsche Classic is actively evaluating the feasibility of using 3D printing for an additional 20 components. The advantages are clear: production can commence based on three-dimensional design data or a 3D scan of the component, enabling on-demand manufacturing and eliminating the costs associated with tooling and warehousing. This innovative approach ensures that even the rarest Cars For Spare Parts can be readily available, safeguarding the future of classic automobiles.
