PORSCHE'S Printed PISTONS - The Printed FUTURE of ENGINE INTERNALS?

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  • เผยแพร่เมื่อ 27 ก.ค. 2024
  • What is up engine heads! Today we are going to be taking a look at a real milestone for engines. A set of 3d printed pistons that recently passed a pretty demanding endurance test in a very serious Porsche engine.
    Watch Mahle's original video: • MAHLE 3D-printed pisto...
    Many people still think that 3D printing is years away from industrial use. But Porsche begs to differ and decided to demonstrate the industrial future of 3d printed automotive parts. Porsche has been 3d printing some stuff for a while now, but it's been stuff like parts of your seat. A piston has to survive extremely high combustion pressures and temperatures all while going up and down thousands of times per minute and rapidly changing direction as it reaches the top and bottom of it's stroke. This why 3d printed seat parts are cute, but 3d printed pistons are an entirely different ball game.
    So Porsche gathered the cream of German engineering seriousness. Big names like Mahle, Trumpf and Carl Zeiss. Together with Porsche they tackled the challenge of designing, manufacturing and testing a set of 3d printed pistons for the fastest 911, the GT2 RS. When it comes to Porsche it doesn't get much better and much faster than this car. So if a set of 3d printed pistons can survive in it's engine, it can likely survive pretty much everywhere else
    The pistons underwent an endurance test which included 135 hours under full engine load and this is no small feat when you remember that the engine in the GT2 RS is a 3.8 liter twin turbo flat six whose full load produces 700 metric horsepower at 7000 rpm with the help of 1.55 bar of boost. (22psi)
    Porsche claims that the pistons passed the test with flying colors and although they are not production ready yet and you likely won't seem them in large scale production Porsche cars just yet, the technology is here to stay and the test is proof that 3d printing has a very promising future in engine internals.
    3d printing technology allows the pistons to have material only in areas which are subject to high forces and stresses which means the pistons can be made ligther. These pistons managed to get 30 additional horsepower out of an already very high strung engine. A very nice feature they have is an integrated oil cooling channel passing right underneath the piston crown. This is something that is simply impossible to make on a forged piston. And because the piston runs 20 degrees cooler thanks to this duct you also reduce the chance of knock which means you can further advance ignition timing. This coupled with lighter pistons also means you can rev the engine higher and voila, 30 more horsepower.
    The pistons are created in a high-precision Trumpf TruPrint 5000 (I said 3000 and displayed 3000 machine footage in the video - this is a mistake) laser 3D printer that basically builds the parts 0.02 to 0.1 millimetre layer at a time by fusing a fine metal powder with lasers. The material used for the pistons is a proprietary alloy called M1174+ this an alloy developed and provided by Mahle.
    Before chucking these things into an engine Porsche really wanted to make sure they are absolutely up to spec so they got Carl Zeiss to to test and measure the pistons with light microscope inspection, electron microscope scanning, X-ray microscope and 3D scanning. I honestly don't know what's the difference between all of these technologies, but it's pretty obvious they really wanted to make sure that the pistons don't fail.
    So we know that these pistons are 10% lighter and they have a nice oil cooling duct that helps them run 20 degrees cooler. But what about strength? Porsche doesn't give us any data here, they just say that they are "extremely strong" and " comparable to those of cast materials for production pistons". So this likely means that when it comes to things tensile strength and ductility, these printed pistons are likely weaker than a set of forged pistons, but that actually only matters when knock occurs. These pistons are likely more brittle than a set of forged ones, and would likely crack when exposed to knock sooner than a set of forged pistons. But that doesn't matter if knock never happens. The GT2 RS isn't running DIY mega-squirt, it's running state of the art engine management that makes sure knock doesn't actually happen.
    It might seem contradictory but new technologies will allow us to squeeze out even more potential from the ancient engines we still love and tune today.
    A special thank you to my patrons:
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ความคิดเห็น • 263

  • @JoshuaFoy
    @JoshuaFoy 4 ปีที่แล้ว +33

    This technology has so much promise in so many fields such as aerospace , but mass production will ensure the old methods stay around.

    • @phlodel
      @phlodel 4 ปีที่แล้ว +3

      Just a matter of time. 3D printed parts will eventually be completely finished in the printer, eliminating machining and other finish processes.

  • @randomdriver
    @randomdriver 4 ปีที่แล้ว +38

    3D printed parts have been in use in aviation for a some time already. Like GE does make fuel nozzles for jet engines with 3D printing and at least Airbus has some 3D printed parts too.

    • @flat_spin_engineering
      @flat_spin_engineering 4 ปีที่แล้ว +3

      There are also 3D printed turbine blades with fancy cooling inside for turbo jet engines. They are made from alu - titanium composite.

    • @madmax2069
      @madmax2069 4 ปีที่แล้ว +1

      Exactly, I was going to say the same thing.

  • @1crazypj
    @1crazypj 3 ปีที่แล้ว +6

    I remember reading about F1 'printed' pistons several years ago. It took over 3 months for each one back then using a similar set up. Even less information available about materials though.

  • @caribbeangtr8077
    @caribbeangtr8077 4 ปีที่แล้ว +8

    I can see how the 3D pistons with 20% lighter would do well in normally aspirated engines, especially coupled with light titanium rods. It could deliver super quick response rpm. I like the development of this technology and its potential.

  • @magpieblue
    @magpieblue 4 ปีที่แล้ว +31

    Car and tech news presented by you is an enjoyable experience! You deliver great quality productions, with relevant footage (unlike most big youtube channels) and you go into the detail. No doubt because you're passionate about that too.
    One of the reasons why Boost School is enjoyable to me is that you're as passionate and interested in the teaching as you are in the subject.
    Now... How do we get you one of those printers? ;)
    Also wanted to show a little love for your little MR2. Barely functional and bargain basement, but so much fun and arguably more fulfilling because of the effort you put in and the connection formed with it.

    • @d4a
      @d4a  4 ปีที่แล้ว +2

      Man I want that Trumpf thing too, imagine all the stuff we could print for our barely functional cars 😂 Yeah the mr2 is somehow becoming worse the more money I spend on it 🤣 but I wouldn't trade it for the world.

    • @taylorc2542
      @taylorc2542 4 ปีที่แล้ว +1

      This and EE are the best on YT.

    • @jimmythepowerful
      @jimmythepowerful 3 ปีที่แล้ว

      jrtpf he does, because he’s a real man and not a basement dweller like you :) did mommy make you breakfast today ?

  • @stevenjohnson4283
    @stevenjohnson4283 3 ปีที่แล้ว +4

    3D printing is actually a manufacturing process used to make medical devices, aircraft parts and who knows what else. 3D printing metal parts is in use because you can now create parts which would be impossible to machine or cast. Its the same with plastic printing because plastic is injected into a mould, and a printer can make any conceivable design.

  • @maneki9neko
    @maneki9neko 4 ปีที่แล้ว +3

    Being able to put an oil gallery inside the crown of a piston is truly 'next level'. This is a really interesting little video. I am enjoying this series so far.

  • @AllBoardCreatives
    @AllBoardCreatives 4 ปีที่แล้ว +93

    You wouldn't download a piston! ...right?

    • @d4a
      @d4a  4 ปีที่แล้ว +13

      Good one!

    • @802Garage
      @802Garage 4 ปีที่แล้ว +2

      OMG. Great reference.

    • @cujbaion1
      @cujbaion1 4 ปีที่แล้ว +1

      Approximately 1Gb taking into account number of layers

    • @kopronko
      @kopronko 4 ปีที่แล้ว

      ;-)

    • @XStuntManiac
      @XStuntManiac 3 ปีที่แล้ว +4

      "-Maaan, my car's blown a piston recently!
      -Just download a new one lol"

  • @andrewmurray6772
    @andrewmurray6772 4 ปีที่แล้ว +9

    now i can build that 1000hp Lada engine i always wanted to build....haha ! Very informative as always mate, cheers from Australia ! :)

  • @TopiasSalakka
    @TopiasSalakka 4 ปีที่แล้ว +24

    Can't wait for 3D printed pistons for my 1.5L Mazda.

    • @diesistkeinname795
      @diesistkeinname795 4 ปีที่แล้ว +1

      Or a 3D printed cylinder head for the 1ZZ-FED as well as some printed pistons and conecting rods.

    • @TopiasSalakka
      @TopiasSalakka 4 ปีที่แล้ว

      @@diesistkeinname795 I'd actually like to see Freevalve heads for older engines, like BP, 2JZ, etc.

    • @diesistkeinname795
      @diesistkeinname795 4 ปีที่แล้ว

      @@TopiasSalakka 2JZ allready has a huge aftermarket, 1ZZ has next to nothing and what it has is expensive and requires international shipping.

    • @TopiasSalakka
      @TopiasSalakka 4 ปีที่แล้ว +1

      @@diesistkeinname795 Didn't say it would have to be limited to those engines...

    • @diesistkeinname795
      @diesistkeinname795 4 ปีที่แล้ว

      @@TopiasSalakka The great advantage of 3D-printing is that you don't need new tooling for each slightly modified part.
      You can print the head for a 1ZZ on the same printer you print B16 and 1.8T heads on.
      Hell, you can even go so far as to use mostly identical combustion chamber and valvetrain designs and just adapt bore size/spacing and other block related design elements.
      So one could commit the herresy of fitting Honda K-series style heads to an LS, because they flow better and are more reliable at high rpm.

  • @aaronwilliams6165
    @aaronwilliams6165 4 ปีที่แล้ว +5

    That is awesome! I never knew that 3D printing could make something that strong. Best break down ever 10:10

  • @codymoncrief8478
    @codymoncrief8478 4 ปีที่แล้ว +1

    I think it was Bugatti that made 3D printed brake calipers if I’m not mistaken. The process for powdered/sintered metal generally makes stronger parts than casting, so If we assume that only structurally unnecessary metal was removed, they should still be overall stronger than cast, and since they are lighter, they also undergo less force, giving a larger margin of strength. The cooler deck heat of the piston would also reduce the likelihood of knock. This really is some next-generation engine design.
    I’m excited to see 3D printed cylinder heads and manifolds soon.

    • @leneanderthalien
      @leneanderthalien 4 ปีที่แล้ว +1

      Yes Bugatti did it, but metal printing is more and more use to made aircraft engines parts, SAFRAN , and specialy he's Turbomeca division (helicopter turbines), use this technique for some parts on the newest engines..

  • @ajayattul5692
    @ajayattul5692 4 ปีที่แล้ว +5

    Innovative wisdom gained here my friend!!!

  • @redfield8758
    @redfield8758 4 ปีที่แล้ว +7

    BMW also has a 3D printed part (I think it is the head gasket) on the new S58 engine for M3/M4.

    • @Hydrazine1000
      @Hydrazine1000 4 ปีที่แล้ว +1

      Yes, but there they print the parts that are used in otherwise conventional casting. It allows for an engine head, or heads, with really complicated internal shapes, which would be impossible to make using conventional casting mould construction methods, but the metal shaping process is still conventional casting.

  • @chadspargo3064
    @chadspargo3064 4 ปีที่แล้ว +1

    Great video, thank you for the look at an interesting new development.

  • @bradcomis1066
    @bradcomis1066 3 ปีที่แล้ว +1

    Can you even imagine how expensive these would be at the dealer? 😱 Very cool to see Porsche actually put these in PRODUCTION. Low volume sure, but this is not just an engineering study, so this is a big move actually.

  • @codyblea3638
    @codyblea3638 3 ปีที่แล้ว +1

    Again, another amazing video. Great info, beautifully edited, and that perspective of the future. Keep it up bro, I rather get my info from an optimistic realist, than a hype train without brakes.

  • @Ellesmere888
    @Ellesmere888 4 ปีที่แล้ว +4

    Fascinating ... Thank you.

  • @meinwarcrafttagebuch5142
    @meinwarcrafttagebuch5142 4 ปีที่แล้ว +1

    as far as I am aware it is not a Porsche but Mahle project. But I agree that it is very impressive.

  • @sabercruiser.7053
    @sabercruiser.7053 4 ปีที่แล้ว

    THE SCENE OF DANCING ABSOLUTELY NAILED IT.THANK U A LOT FOR YOURE GREAT WORK THAT U DID DONE AND U ARE KEEP IN DOING IT

  • @captnjaygreybeard6394
    @captnjaygreybeard6394 4 ปีที่แล้ว +1

    Enjoyed the vid, thanks

  • @fridaycaliforniaa236
    @fridaycaliforniaa236 11 หลายเดือนก่อน +2

    10:10 *Dancing 4 Answers* 🤣

  • @alviolampis
    @alviolampis 4 ปีที่แล้ว

    Channel subscribed! Nice work mate 8)

  • @jamest5149
    @jamest5149 4 ปีที่แล้ว +1

    Aerospace, military, Oil and Gas companies, Space and DNVGL all see 3D printing as a ‘now’ manufacturing technology already... saves the cost of shipping and or storage of items, it can 3D print on demand where it is required anywhere in the world. DNVGL are doing certification services for 3D printed components and companies.

  • @emil55555555
    @emil55555555 4 ปีที่แล้ว +21

    135 hours at redline? whaaat

    • @d4a
      @d4a  4 ปีที่แล้ว +13

      Not bouncing the limiter, just full load, basically WOT at max output.

    • @emil55555555
      @emil55555555 4 ปีที่แล้ว +4

      @@d4a its often close thow on turbo engines. You make really intresting videos and good videos. thank you. There is a game out there called automation i think you would love it. You can build engines in it and mess around with almost everything. materials valves boost comp. Check it out if ur intrested.

    • @emil55555555
      @emil55555555 4 ปีที่แล้ว

      not a sponsor or anything just like the game a lot

    • @richardcaldwell6159
      @richardcaldwell6159 4 ปีที่แล้ว +2

      That oil channel is connected with a tube? Interesting. That means that electrical components of significant wattage could also be included in a piston head, right?
      My engine goes well. Patent filing is about a week away. Your videos have helped immensely. If you want a preview let me know. (And I'd appreciate your input)

    • @d4a
      @d4a  4 ปีที่แล้ว +2

      @@emil55555555 I did play automation a bit, it's fun no doubt.

  • @elefanti1987
    @elefanti1987 4 ปีที่แล้ว

    Nice art on the background!

  • @morelanmn
    @morelanmn 4 ปีที่แล้ว

    Well done, Very well done.

  • @jameshaulenbeek5931
    @jameshaulenbeek5931 4 ปีที่แล้ว

    That's pretty impressive!

  • @Theseones
    @Theseones 4 ปีที่แล้ว

    Man I fucking love your videos, never stop making them!!

  • @garyrowe58
    @garyrowe58 4 ปีที่แล้ว +3

    Koenigsegg have been producing parts this way for years

  • @zmanmd1641
    @zmanmd1641 4 ปีที่แล้ว

    Next up - hollow 3D printed connecting rods with oil cooling channels to go with those 3D printed pistons. With a lighter, cooler and stronger rotating mass, higher RPM's and hotter tunes means more HP all around. The lighter mass means better fuel mileage, the holy grail for keeping powerful engines in production with increasing emissions standards. Imagine a hollow RX-7 rotor, able to spin to 15k rpm and weighing 50% less than standard. Lots of applications to give more power and torque plus better fuel mileage.

  • @andrewlace
    @andrewlace 4 ปีที่แล้ว

    Cool inbuilt oil gallery. An incredible feature.

  • @EdgarsLS
    @EdgarsLS 3 ปีที่แล้ว

    I get why Porche played it safe, they probably said "ehhh... well you know... it's plastic, be easy on it..." like 100 times :D

  • @HootMaRoot
    @HootMaRoot 4 ปีที่แล้ว +1

    They have been 3d printing rocket engines for the last few years so it's about time that the technology made its way into the automotive industry

  • @alexduncan9941
    @alexduncan9941 4 ปีที่แล้ว

    I love the reminder at 10:10 to look at the future through "Roses"-tinted glasses. :-D

  • @EdgarsLS
    @EdgarsLS 3 ปีที่แล้ว

    I can't believe I just recently found your channel. I mean your channel is what I always have dreamed of watching, you explain stuff in a not super 'dumbed-down' way, are really entertaining (at least I think so), and even mention lada engines xD,
    but I've seen people getting 300hp out of those NA Lada engines, but that's by boring and stroking the block to 1950cc's, which is kinda cheating xD.
    wouldn't be surprised if there's like 700hp turbo lada engines somewhere.

  • @larrysorenson4789
    @larrysorenson4789 4 ปีที่แล้ว

    Honeywell in Phoenix has been 3-D printing critical jet engine parts for around five years. They are fully committed to the technology.

  • @n.prince2458
    @n.prince2458 2 ปีที่แล้ว

    Not bad. I see you didn't cover billet pistons.
    A) How does billet pistons compare to forged and cast?
    B) Do billet pistons improve fuel economy?
    C) Are billets less prone to flapping during cold start ups?
    D) Where does it measure up in ductile Strength?
    E) What are the Pros and Cons?

  • @blkdna748
    @blkdna748 3 ปีที่แล้ว

    Technology is growing. I love the cooling of piston. It's cool nd genius.

  • @justpassnthru
    @justpassnthru 3 ปีที่แล้ว +1

    I predict that one day the local parts store will keep no parts on the shelf. You will request a certain part and they'll just print it up for you.

    • @d4a
      @d4a  3 ปีที่แล้ว

      That would be seriously cool!

  • @Umbravi
    @Umbravi 3 ปีที่แล้ว

    This kind of printing is called Selective Laser Sintering (SLS) and has been around since the 80's. SLS parts that need to be strong also need to be extensively heat treated in a special process that has the part absorb brass(for steel) to make the ~80% density part 98+% dense, producing much weaker parts than forged or billet and likely slightly weaker than cast.
    I'm glad Porsche is pushing forward, but it's still a long way off.

  • @walangchahangyelingden8252
    @walangchahangyelingden8252 3 ปีที่แล้ว +1

    The grain structure problem is another thing holding 3d printed parts back.

  • @HandIeThese
    @HandIeThese 4 ปีที่แล้ว +8

    2050 here. there's a tutorial to make 3D printed cars now!
    there's a reference here...

  • @NeedDrPhil
    @NeedDrPhil 4 ปีที่แล้ว +1

    holy shit the dance with the engine stand. bless u miata bois.
    thankyou so much for all your videos, fangirl/boying pre hard~

  • @Hydrazine1000
    @Hydrazine1000 4 ปีที่แล้ว

    What you completely forgot to add though, is the fact that Porsche Classic has been busy for a few years now offering certain 3D printed out-of-stock classic Porsche parts for rare and therefore expensive vintage Porsche classics. Some sought-after vintage parts, for which the tools, dies or moulds were no longer available so they can't be reproduced by conventional means, are once again officially available from Porsche Classic as 3D printed part.

    • @d4a
      @d4a  4 ปีที่แล้ว

      I did not "completely forget" that. I said Porsche had been printing for a while "but it's MOSTLY been stuff like parts of your seat". The stuff that's offered through Porsche classic is similar too, none of it is engine internals or parts that see significant stress.

    • @Hydrazine1000
      @Hydrazine1000 4 ปีที่แล้ว

      @@d4a See newsroom.porsche.com/en/company/porsche-classic-3d-printer-spare-parts-sls-printer-production-cars-innovative-14816.html The Porsche 959 clutch release lever is originally a grey iron cast part with very high quality requirements. It has to be able to withstand a load of nearly 3 tonnes. Porsche offers that now as an additively manufactured part, fully conform their original part specifications. That's quite something else than non-critical or lowly stressed parts.
      And, sorry, you're right, you didn't "completely forgot" to mention, it's just that Porsche is doing more with additive manufacturing than you implied.

  • @bryantv2410
    @bryantv2410 4 ปีที่แล้ว

    I won't believe it until I see it in person.

  • @ericjbowman1708
    @ericjbowman1708 2 ปีที่แล้ว

    My understanding is that 3D-printed pistons are hypereutectic, but this wasn't mentioned in the video. I don't know if this is a limitation of the 3D-printing process, or the source powder. But I do think it's important to note that the thermal expansion coefficient of 3D-printed pistons is along the lines of cast pistons, not forged pistons, probably due to the high silicon content i.e. hypereutectic.
    Can one add Nickel to the powder and 3D-print a Nikasil piston? Not sure why you'd want to, just a hypothetical. So is incorporating Molybdenum into the skirt matrix. I think within a few years we'll be trading data files for printing up new pistons in our home garages. Especially those where the pinhole intersects the oil ring, which has a "ring support" allowing for higher rod/stroke ratio due to shorter compression height.

  • @mrburgermaster
    @mrburgermaster 4 ปีที่แล้ว

    I'm excited for the major weight loss of the piston while maintaining strength. High revving, longer stroke will now be much easier to achieve.

  • @802Garage
    @802Garage 4 ปีที่แล้ว +5

    You work for Hello Kitty key chains eh? Things about you I didn't need to know. ;)

    • @d4a
      @d4a  4 ปีที่แล้ว +3

      We all have our secrets. Some are darker than others 😂

    • @802Garage
      @802Garage 4 ปีที่แล้ว +2

      @@d4a I'll stick by you in darkest of times, no worries. Hahaha.

    • @d4a
      @d4a  4 ปีที่แล้ว +3

      I love you man. I really do

    • @802Garage
      @802Garage 4 ปีที่แล้ว +2

      @@d4a 😍😭 You haven't forgotten me when you got famous. That's real friendship haha. Much love.

    • @d4a
      @d4a  4 ปีที่แล้ว +2

      Famous? We're objectively both still guppies in the YT ocean 😂

  • @pujiri5752
    @pujiri5752 4 ปีที่แล้ว +2

    10:10 WTF😂

  • @thorvelasco1467
    @thorvelasco1467 2 ปีที่แล้ว

    Antoni Gaudi of Sagrada Familia Basilica in Spain: Porsche, hold my sangria!

  • @Adrian_The_Great
    @Adrian_The_Great 4 ปีที่แล้ว +1

    One day you could talk about pistons and their true shape and the reason behind it.

    • @d4a
      @d4a  4 ปีที่แล้ว

      How they're not actually round? Good idea! Thank you

  • @gaspuppygarage3782
    @gaspuppygarage3782 3 ปีที่แล้ว +1

    I"ll take that oil cooling ring on my 2.3L vw type 1 as well. Lol

  • @johncunningham4820
    @johncunningham4820 2 ปีที่แล้ว

    3D printing IS Star Trek Replicator 1.0 . Seriously ! If this was done , then 1.01 at this stage .
    I heard that Koennigsegg designed one of their Engines , using a Twin-Scroll , Variable Turbocharger that couldn't be produced by conventional methods .
    So they 3D printed it in Some Grade of Stainless Steel . Other than Annealing , no finish machining POSSIBLE internally . No idea if this really happened .
    Koennigsegg . Lunatics . SMART lunatics . With a Very PHAT cheque-book .
    For these Pistons , the Heat treatment would HAVE to be an Annealing process I think and then , maybe a Hardening Flash , AFTER machining .
    Really interesting stuff .

  • @jaybury5760
    @jaybury5760 4 ปีที่แล้ว +4

    So it's basically a sintered piston with 3D CAD design hm? Wonder how material science will advance and find the variation of range for compressive and shear strengths.

    • @Hydrazine1000
      @Hydrazine1000 4 ปีที่แล้ว +1

      Materials scientist with "additive manufacturing" knowledge here. About a decade ago, the laser power and optics were such that 3D metal printing was SLS, selective laser sintering. With both improvement in optics as well as laser power, it has been SLM for years now, so selective laser *melting* where the temperature of the powder at the focal point of the laser gets past sintering temperature, which is by definition below melting point, to fully locally melting. So, no, this isn't a sintered part. SLM typically results in mechanical properties that exceed those of cast material, because cooling speeds are much better than conventional casting, but the properties don't quite reach the mechanical properties of forged material. But, since you have near perfect degree of freedom in shape, when 3D printing, you can not only leave out material where it's not needed, you can selectively add it where you do.

  • @JackBWatkins
    @JackBWatkins 3 ปีที่แล้ว +1

    So instead of waiting for parts from who knows where to arrive at my door, I can go to NAPA or O’Rylie’s and in a few hours or minutes pick up my printed parts. Cool

  • @jozsefizsak
    @jozsefizsak 4 ปีที่แล้ว +1

    Fascinating. Put me down for an oil pickup for the 1MZ-FE that doesn't suck air during hard cornering resulting in a spun rod bearing. You could sell dozens of those, so a perfect application of 3D printing.

    • @d4a
      @d4a  4 ปีที่แล้ว +1

      I came up with at least 5 good business ideas as I was making this video. Now I just need the 2 million Euros for that Trumpf printer :)

    • @jozsefizsak
      @jozsefizsak 4 ปีที่แล้ว +2

      @@d4a I'm looking under the sofa cushions right now but I'm not terribly optimistic. And it's only 2 million? Damn, so near yet so far.

    • @redfield8758
      @redfield8758 4 ปีที่แล้ว +1

      @@d4a You will also need MAHLE magic powder compound... Do they actually sell it anyway ?

    • @d4a
      @d4a  4 ปีที่แล้ว

      @@redfield8758 No, but there's a guy on a street corner near me who offered me some magic powder once. It's the same thing right?

  • @ghoulbuster1
    @ghoulbuster1 4 ปีที่แล้ว

    Don't think the combustion engine is done yet!
    This technology is absolutely massive news, and a huge improvement in internal design.
    Being able to create ANY internal that you want, without the limitation of forging or casting, will be extremely important in the advancement of pistons.
    This can and WILL help develop better engine in all applications! From Tiny bike engines to huge industrial power generators!

    • @d4a
      @d4a  4 ปีที่แล้ว

      Exactly! That's the real gist of it.

  • @listerine-pr5lt
    @listerine-pr5lt 4 ปีที่แล้ว

    What Porsche does can be done to any technology meaning to improve it another notch for the cost of several times more price but many areas people won't pay that much money to get a more advanced one.

  • @mi3antrop_316
    @mi3antrop_316 2 หลายเดือนก่อน

    Oh, man. I'm from Russia and I was really loud when you said lada.
    Btw one shop in Russia makes exhausts and some other custom 3d printed parts.

  • @fluxingn
    @fluxingn 4 ปีที่แล้ว +1

    Please talk abut the 1NZ-FE. People rarely bring it up. I was very surprised by how snappy the engine was , considering that it is only a 1.5L. I am interested about ways to improve on this engine. Is there a way to increase its displacement by building a Frankenstein engine of sorts?

  • @AmaroqStarwind
    @AmaroqStarwind 3 ปีที่แล้ว

    I might fill any remaining cavities in a 3D-printed part with aerogel, just because I'm slightly paranoid of having so much empty space in there, but I don't want to completely negate any weight savings. Aerographene is very lightweight.

  • @andrewallen9993
    @andrewallen9993 3 ปีที่แล้ว

    The cream of German engineering talent were hired by Porsche!
    And they designed the IMS bearing that way :(

  • @rahulmenon6073
    @rahulmenon6073 5 หลายเดือนก่อน

    3:03 lol 😂

  • @jeckjeck71
    @jeckjeck71 3 ปีที่แล้ว +1

    help! @ 10:10 what's the title of the song? thanks!

  • @keshmo12
    @keshmo12 4 ปีที่แล้ว

    How do you get oil up through the bottom of the piston? Some oil squirter? Never thought of that as a cooling option.

    • @d4a
      @d4a  4 ปีที่แล้ว +1

      Yes, an oil squirter. Many conventional engines have them too, in most cases they basically squirt oil to the underside of the piston to cool it. This goes one step further by getting oil into the piston, right under the crown and next to the ring land, to further improve cooling.

  • @3800S1
    @3800S1 4 ปีที่แล้ว

    I have had exterior body moulds for my car reproduced in the original factory material using SLS 3D printing.
    Simply becasue the replacement parts didn't exist.

  • @slaps101
    @slaps101 4 ปีที่แล้ว

    I heard a few whispers years ago that Mahle was making iron 3D printed pistons for Ferraris v6 hybrid F1 engine.

  • @yusufkuntoro3141
    @yusufkuntoro3141 3 ปีที่แล้ว

    I think with 3d printed piston allow manufacture to make kind of piston size and design, so custom piston can be made easily

  • @mediocre-motorcycle-modifi6818
    @mediocre-motorcycle-modifi6818 4 ปีที่แล้ว

    How does that oil gallery work?

  • @SuzukiS1300
    @SuzukiS1300 4 ปีที่แล้ว

    G13B is missing there :)

  • @Tj930
    @Tj930 4 ปีที่แล้ว

    Great video! Lotz of jokez 😉😂😊

  • @ebutuoy8272
    @ebutuoy8272 4 ปีที่แล้ว

    Would have loved to have that 1000HP Lada Motor in my Niva

  • @harley8918
    @harley8918 4 ปีที่แล้ว +1

    what effect would the oil in the cooling duct have on the balance of the rotating assembly, given that the weight of that volume of oil will change slightly due to temperature fluctuations and the accumulation of contaminants throughout the life of the oil?

    • @redfield8758
      @redfield8758 4 ปีที่แล้ว

      Also, oil inside the piston will actually make it more heavy right ?

    • @harley8918
      @harley8918 4 ปีที่แล้ว +1

      @@redfield8758 yes but I am sure they would factor in the weight of the oil when calculating the bobweight for balancing

    • @redfield8758
      @redfield8758 4 ปีที่แล้ว

      @@harley8918 needs to use the same oil (like in any car you will tell me)
      Also, I imagine oil density changes with temperature ? (Edit : sorry, you already said it above)
      But most problematic, like you said, would be the running of oil itself in the duct, disrupting balance.

  • @bryanst.martin7134
    @bryanst.martin7134 3 ปีที่แล้ว

    Was going to ask if they sintered them after printing. A technique that homogenized the layers into 1.

    • @glitchyikes
      @glitchyikes 2 ปีที่แล้ว

      Parts come out of a laser 3D printer such as above need not be sintered but need heat treatment to redo all the internal grain structure. There are some 3D printing technologies that still have binder on the printed parts, thus will need sintering, but not those in the video

  • @Stale_Mahoney
    @Stale_Mahoney 4 ปีที่แล้ว

    advancing ignition on a old engine as pistons run cooler, and lighter internals as well now if this does not sound like a reasion to keep upgrading and have those old piston slappers around i dont know what does xD but also running coolce would in theory allow you to run leaner as well if you dont advance ignition to much so maybe you would be able to maintain stock power and have bether fuel economy as well?

  • @Stelios.Posantzis
    @Stelios.Posantzis 3 ปีที่แล้ว

    Two questions:
    a) Is there any information available on the carbon footprint of 3-d printing production of pistons vs casting (vs forging) as I guess that will be one of the deciding factors in the long term for the technology viability at industrial scale and
    b) where can I buy a '87 MR2 for $600? (assuming it's not totalled/run to the ground)

    • @d4a
      @d4a  3 ปีที่แล้ว +2

      1) That's a valid point and a really good question, but I wouldn't know where to find such research. I have seen some 3d printer manufacturers claiming how the 3d printing carbon footprint is very low, but that's just blowing one's own horn. Plus, it's really difficult to get an accurate comparison because it's very hard to draw the line for the process, where does each actually start? Plus, the practices for sourcing the raw materials vary heavily across the world. Getting the comparison right would be a massive undertaking. But I'm sure that something will be done, if it hasn't been done already.
      2) the days of 600$ Mr2s are long gone

    • @Stelios.Posantzis
      @Stelios.Posantzis 3 ปีที่แล้ว

      ​@@d4a You're right, such research could only come from the manufacturers themselves and only once they have decided to adopt the technology. I would assume it would include the carbon footprint of the printer itself probably amortized over its useful lifespan and including the carbon footprint of recycling/dumping it. Also, the metal particles themselves I would imagine would have a different footprint from that of ingots.
      I was actually thinking of the 00+ model. Cheapest I could find in Greece currently is 2.5k EUR. Not bad but mileage is quite high.

  • @mikethecarguy9387
    @mikethecarguy9387 4 ปีที่แล้ว

    i can not speak for porsche, but 3d printed metals are usualy stronger than most other types. because the metal is superheated quickly by a laser, it offers a much better structure guide, than just pouring liquid metal. (think atomic layers) again, not sure about porsche, but because most 3d printed metals are exposed to this short, but very high burst of heat/energy, impurities are burned off leaving little randomness or "dirty metals". a good example is titanium. a 3d printed titanium part is the strongest humans can make from this metal. cast, molding, milling,etc... are actualy weaker than the 3d version.

  • @darkoneforce2
    @darkoneforce2 4 ปีที่แล้ว

    Electron beam welding 3D printing should be close(r) to forged the laser synth.

  • @sakisgeo3253
    @sakisgeo3253 4 ปีที่แล้ว

    Have you ever heard about Extreme tuners and Spyros Panopoulos Automotiv?!?!
    They have made same pretty cool 3d printed stuff as well

    • @d4a
      @d4a  4 ปีที่แล้ว

      Heard about him, does a lot of generative design. Has the car been revealed?

  • @cantho11
    @cantho11 3 ปีที่แล้ว

    There's new type of 3d printing machine that can Print metal in minutes

  • @cavalierliberty6838
    @cavalierliberty6838 3 ปีที่แล้ว

    They need to make 3d printed cranks now

  • @cousinfester4621
    @cousinfester4621 4 ปีที่แล้ว

    Understated humor included. What's not to like?

  • @themistoklisanastasiadis
    @themistoklisanastasiadis 4 ปีที่แล้ว

    Have you seen the CHAOS from Spyros Panopoulos? Greek manufactured, 3d printed internals. pretty interesting.

    • @d4a
      @d4a  4 ปีที่แล้ว

      Yes, generative design, amazing stuff. Has the car been officially fully unveiled?

    • @themistoklisanastasiadis
      @themistoklisanastasiadis 4 ปีที่แล้ว

      @@d4a I think not yet, although everything is being "muted" due to coronavirus being all over news and social media. Maybe I just didn't see anything new.

  • @michaelhelgeland4588
    @michaelhelgeland4588 4 ปีที่แล้ว

    Mercedes OM617 turbo has oil cooling ducts under the piston crown, they are supplied by oil squirting nozzles. A lot of turbo cars use them now but I believe OM617 turbo was the first production car engine with that technology.

    • @d4a
      @d4a  4 ปีที่แล้ว +1

      I know those pistons have a duct on the underside that looks like the one on these pistons, but I would love to see the cross-section of the OM pistons, I doubt the oil cooling duct on the OM goes full circle?

    • @michaelhelgeland4588
      @michaelhelgeland4588 4 ปีที่แล้ว

      driving 4 answers Yes the om617 ones go full circle I have a cross-section, page 10 of this pdf www.w124performance.com/docs/mb/other/SAE_OM617.95X_Development.pdf

    • @d4a
      @d4a  4 ปีที่แล้ว

      Nice, thanks for the paper. Pretty impressive for 1978. It will be interesting to see if the printed ones pick up on strength and ductility in the near future, we will have the ducts, they won't weigh as much as the cast ones, but could be as strong as the forged ones, imagine that.

    • @V8Lenny
      @V8Lenny 4 ปีที่แล้ว

      Truck and industrial engines have always been ahead of car engines, piston squirters have been used forever.

  • @Beanpapac15
    @Beanpapac15 4 ปีที่แล้ว

    Simply due to the fact that 3D printing has zero economy of scale we're probably never gonna see this in sub supercar production engines. It would be nice to know what percentage of the cost of aftermarket forged pistons is due to forge tooling though, because that's probably what will determine success in the aftermarket. If we can make powdered metal production much more economical in the next 5-10 years it would be surprising if we didn't see at least a few printed pistons crop up for oddball engines.
    The shop I work in has a smaller SLS printer but it doesn't get much use because the material cost typically isn't worth it. People tend to forget that the powder isn't really reusable* so the material cost of a part is much greater than the volume of the part, unlike casting, forging, or conventional plastic 3d printing. I'd like to see them try a binder jet process for the pistons, as that would be more economical.

  • @flyingpeter
    @flyingpeter 4 ปีที่แล้ว +1

    i've been seeing lots of allegedly 3d printed compressor turbines, could this be better than billet?

    • @d4a
      @d4a  4 ปีที่แล้ว +3

      I've seen those too, they have benefits and drawbacks. That's a good video idea actually, thank you :)

    • @Hydrazine1000
      @Hydrazine1000 4 ปีที่แล้ว +1

      As stated elsewhere in this thread: currently 3D printed parts sit in between what you can get in terms of mechanical properties of cast parts and forged parts. It's better than a cast metal structure, but it doesn't quite make it to the strength of forged material. BUT, having said that, the design freedom of 3D printing is almost unrestricted, so you can perfectly optimise a part by adding material only where it's needed. That's impossible with forging or casting, so 3D printing (or "additive manufacturing" as it's called) has the potential to produce better parts, *when you re-design from the ground up* to make use of this design freedom.

  • @stevesloan6775
    @stevesloan6775 4 ปีที่แล้ว

    They’ll probably get stronger overtime at the sacrifice of combustion chamber volume.🍀🤜🏼🤛🏼🇦🇺🤓

  • @georgerobartes2008
    @georgerobartes2008 3 ปีที่แล้ว

    Its nothing more than a high temperature sintering process not unlike printing aerospace components that endure similar loads . It should be no different to a forged piston and has many advantages like oil galleries and unlimited form for structural strength . The traditional method of cooling was to machine a V groove above the oil control ring . Porsche has been using Mahle alloys for many decades typically 375 in the forged variety . I'd like to see the composition of this new Mahle alloy as Rolls Royce has developed numerous alloys suitable for this process that are decades old and with published formulation and as they say imitation is the greatest form of flattery to the worlds most recognised engineering and metallurgical company .
    Nothing wrong with DIY Megasquirt S&S ! Ask 100s of thousands of users that make amazing horsepower numbers from engines without Porsches ££££££s ! We've came a long way since the Zytek system fitted to the stock block Jaguar V12 s trounced the 1100 bhp Porsche 917s in the early 80s .

  • @patrickwendling6759
    @patrickwendling6759 11 หลายเดือนก่อน

    Thank you for your knowledge and videos USA 🇺🇸 USA 🇺🇸

  • @chewylewy1714
    @chewylewy1714 4 ปีที่แล้ว

    I think when 3D printed engine blocks it could be an even more important step

    • @Beanpapac15
      @Beanpapac15 4 ปีที่แล้ว

      If you think billet blocks are expensive just you wait until you see how much a 3d printed block costs

  • @CreatorCade
    @CreatorCade 4 ปีที่แล้ว

    Lol Clint Eastwood isn’t having any of your fancy 3D printed pistons.

  • @IIIRotor
    @IIIRotor 4 ปีที่แล้ว +3

    the "Metric HP" is less than the "Imperial Kw"

    • @d4a
      @d4a  4 ปีที่แล้ว +1

      Yes, bhp is 690

    • @Random-nf7qb
      @Random-nf7qb 4 ปีที่แล้ว

      @@d4a who cares, it would be great if you moved to full metric units.
      Just to stick it up to muricans who completely ignore the existance of the rest of the world.

    • @Random-nf7qb
      @Random-nf7qb 4 ปีที่แล้ว

      @@d4a btw, how did you know lada people watch your videos? :D

    • @d4a
      @d4a  4 ปีที่แล้ว +2

      @@Random-nf7qb There's more Lada people out there than you'd think, never hurts to appease this giant hidden population 😊 Also, full metric is not happening, I'll be sticking to this sort of half half system because my audience is from both sides of the pond, and "muricans" are nice as long as you don't generalise based on what only one group is like :)

    • @Random-nf7qb
      @Random-nf7qb 4 ปีที่แล้ว

      @@d4a ok, btw, watch this(Lada engine):
      th-cam.com/video/wldQn64_-1Y/w-d-xo.html

  • @radodanchev8600
    @radodanchev8600 4 ปีที่แล้ว

    Mi future is to get Lada 2107 and make rally car wit +200Hp from stock engin
    This video will help
    Can you make video what tips of sensors you need to convert from Carb to direkt fuil inqektion

  • @garyhoffmann1615
    @garyhoffmann1615 3 ปีที่แล้ว

    Soon videos like this will have a link for the file on Thingiverse for you to print your own. It has been at least 2 years now since prototype jet engine turbine blades have been successfully 3D printed.

  • @Narblo
    @Narblo ปีที่แล้ว

    I would love to 3d print my own engine at home for my custom motorcycle for at most 10k. Now that would be advancement.

  • @whitehorse1959
    @whitehorse1959 4 ปีที่แล้ว

    E-pistons! Expensive-pistons.

  • @CanDriveSoon
    @CanDriveSoon 3 ปีที่แล้ว

    Anyone else notice the crack in the wrist pin area @7:35?

  • @renz1013
    @renz1013 4 ปีที่แล้ว +2

    I never knew you can print piston heads in fact print heavy duty stuff like those at all dman tech has Gone advanced

    • @ristekostadinov2820
      @ristekostadinov2820 4 ปีที่แล้ว

      there is company that prints engine block th-cam.com/video/hh0fKrTXuN0/w-d-xo.html

  • @kurlyfry7916
    @kurlyfry7916 4 ปีที่แล้ว +4

    Niceeee notification squad!

    • @d4a
      @d4a  4 ปีที่แล้ว +4

      I almost always publish on Sundays, but decided to mix things up a bit this week, hope you guys don't mind :)