Porsche Classic Now Produces Rare Parts Using 3D Printer

Porsche Classic, the division of Porsche dedicated to classic vehicles, has come up with a solution to the problem of producing extremely rare parts that are only needed in small quantities: 3D printers. The Porsche Classic range currently has around 52,000 parts. If a certain part is no longer in stock or its stock is dwindling, it is reproduced using the original tools. For larger quantities, the production may require the use of new tools. However, ensuring the supply of spare parts that are only required in very limited numbers poses a major challenge as producing small batches using new tools would be inefficient. Let's take the Porsche 959, of which only 292 examples were ever produced. The release lever for the 959's clutch is made from grey cast iron, is subject to very high quality requirements, but is in very low demand. To manufacture it now, the only process the German carmaker claims is worth considering would be selective laser melting. To manufacture the release lever, a layer of powdery tool steel less than 0.1 millimeters thick is applied to a processing plate in a computerized process. In an inert atmosphere, a high-energy light beam then melts the powder in the desired locations to create a steel layer. Thus, the complete three-dimensional component is produced, layer by layer. Both the pressure test with a load of almost three tons and the subsequent tomographic examination for internal faults were passed by the printed release lever with flying colors. The practical tests with the lever installed in a test vehicle and extensive driving tests confirm the impeccable quality and function of the component. Due to the consistently positive results received to date, Porsche is currently manufacturing eight other parts using 3D printing. The parts in question are steel and alloy parts produced using the selective laser melting process, and plastic components manufactured using a selective laser sintering printer. Sintering is a process where the material is heated to just below melting point and the remaining energy is applied through a laser to fuse the plastic powder at a selected point. All parts are subject to the quality requirements of the original production period as a minimum, though they usually meet higher standards. Accuracy in terms of size and fit is ensured by performing tests with the part installed. Depending on the area of application, plastic parts made of various materials as in the original must be resistant to oils, fuels, acids, and light. Porsche Classic is currently testing whether 3D printing is suitable for the production of 20 more components. The benefits: a three-dimensional design data or a 3D scan of the component is a sufficient basis to commence production. The components can be produced on demand if needed, thereby eliminating tool and storage costs.