3D printed car is strong as steel, half the weight and nearing production

Wired.uk

Picture an assembly line that isn't made up of robotic arms spewing sparks to weld heavy steel, but a warehouse of plastic-spraying printers producing light, cheap and highly efficient automobiles. 

If Jim Kor's dream is realised, that's exactly how the next generation of urban runabouts will be produced. His creation is called the Urbee 2 and it could revolutionise parts manufacturing while creating a cottage industry of small-batch automakers intent on challenging the status quo.

Urbee's approach to maximum miles per gallon starts with lightweight construction — something that 3D printing is particularly well suited for. The designers were able to focus more on the optimal automobile physics, rather than working to install a hyper efficient motor in a heavy steel-body automobile. As the Urbee shows, making a car with this technology has a slew of beneficial side effects. 

Jim Kor is the engineering brains behind the Urbee. He's designed tractors, buses, even commercial swimming pools. Between teaching classes, he heads Kor Ecologic, the firm responsible for the 3D printed creation.

"We thought long and hard about doing a second one," he says of the Urbee. "It's been the right move."

Kor and his team built the three-wheel, two-passenger vehicle at RedEye, an on-demand 3D printing facility. The printers he uses create ABS plastic via Fused Deposition Modelling (FDM). The printer sprays molten polymer to build the chassis layer by microscopic layer until it arrives at the complete object. The machines are so automated that the building process they perform is known as "lights out" construction, meaning Kor uploads the design for a bumper, walks away, shuts off the lights and leaves. A few hundred hours later, he's got a bumper. The whole car — which is about three-metres-long — takes about 2,500 hours.

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