The 5 Stages of Car Design with Multi-Material 3D Printing

The 5 Stages of Car Design with Multi-Material 3D Printing

“Project Bleu”


CATIA Project Bleu 5 Stages of Automotive Prototyping and Design


“Project Bleu” is a 5-part car design study in physics, design and modelin taken on by the CATIA software division of Dassault Systèmes in order to show potential customers the ability to prototype an automobile. 

CATIA software, a division of Dassault Systèmes, creates 3D CAD modeling software, which is a leading tool in the aerospace and automotive industries. The “Project Bleu” team challenged themselves to undertake a typical automotive design cycle, from sketch to 3D Printed prototype. 

The team consisted of a creative designer, two concept modelers, two visualization experts, two class A surfaces modelers, one mechanical modeler, and of course the Objet260 Connex multi-material 3D printer. The 33 micron resolution and multi-material capabilities allowed the team to cross check and validate the digital design. 

The final output was a variety of 3D printed models representing five distinct stages of automotive product development highlighted below. 


Stage 1: Concept DevelopmentMiniature cars were 3D Printed at 5 cm in length in order to catch basic design flaws. 
Stage 2: Proportion Studies10 cm models were 3D printed in order to ensure different design elements worked together. 
Stage 3: Speedform ModelA speedform model was created to test the aerodynamics of the car in a wind tunnel. 
Stage 4: Detailed ModelA complete model with exterior features such as mirrors, bumpers, and tires.
Stage 5: Functional PrototypeA 3D printed model complete with moveable chasis and wheels. 

 


 

“Project Bleu” Design Stages

3D Printed Scaled Car Models in Polyjet CATIA automotive rapid prototyping
A scaled down model at 10 cm used for design validation
Objet260 Connex Multi Material polyjet 3D printed car models
Stripped-down speedform models for aerodynamic testing
3D Printed Car Models CATIA automotive rapid prototyping
A functional prototype of the car, all 3D printed.
3D Printed Car Tires in Rubber CATIA automotive rapid prototyping
Multi-material tire components printed in rubber as a single piece with the Objet260 Connex.

 


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Take a look at some of our other 3D printed projects, made with more powerful and durable 3D printers and materials.

 

3D Printing and 3D Scanning 1927 Ford Model T for restoration 3D Wheels are in Motion

Utilizing 3D scanning and 3D printing technologies we were able to capture and replicate a historic 1927 Ford Model T.​

3D Printed 1927 Ford

3D Printed Mountain Bikes Trek

Chasing Perfection: The Trek Story

To celebrate the launch of the 2013 Man of Steel movie premiere the Proto3000 team 3D printed our very own Kryptonite

3D Printing for Mountain Bike company Trek

 


 

 

 

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