Printing the car of the future

The Breton Genesi LSAM CNC machining centre
Filippo Guerra
The Breton Genesi LSAM CNC machining centre

Italian machine tool supplier, Breton continues to introduce revolutionary technologies that open up new horizons for additive manufacturing applications. Composites in Manufacturing reports.

The first zero-emission concept car called Project Arrow has been launched in Canada. It is a fully functional vehicle whose chassis was designed by Automotive Parts Manufacturers' Association (APMA) and Xaba Inc. and 3D printed with Breton Genesi.

The futuristic zero-emission electric concept car 'Project Arrow', launched by the Automotive Parts Manufacturers' Associations (APMA), was unveiled at the Consumer Electronic Show (CES) in Las Vegas, at the beginning of 2023.

The electric SUV's innovations also include a 3D-printed chassis using Breton Genesi technology to realise the concept car, which is not only a prototype but also a fully functioning vehicle.

The Project Arrow zero-emission concept car
The Project Arrow zero-emission concept car

APMA selected companies capable of providing the most advanced technologies to contribute to the ecological transition into the mobility sector. The car chassis was designed by APMA in collaboration with Xaba, a Canadian company dealing with innovative technologies, and was 3D printed and milled on a Breton Genesi CNC machining centre.

APMA, together with Xaba, found all the necessary know-how in the innovative Breton Genesi system, which combines artificial intelligence and machine learning, as well as integrating the subtractive system into the additive one to further evolve 3D printing techniques.

The car will be used as a mobile showroom of the innovative technologies implemented by the project's partner companies, including Breton, during a two-year roadshow that will take Project Arrow to various events and car shows around the world. This year it will visit Toronto, Montreal, Detroit, Palo Alto, Las Vegas and San Antonio.

It was a challenge that involved more than 50 companies, 97% of which are Canadian, three governments and hundreds of engineers, project managers, designers and students, moved by the common instinct to anticipate the future.

It all adds up

The benefits of additive manufacturing include: freedom of design and without the limits of subtractive machining; fast prototyping; just-in-time and on-demand production.

Breton Genesi is among the first 3D printer series for the large scale production using large scale additive manufacturing (LSAM) techniques. Starting from the analysis of extrusion processes, Breton has developed a wide range of CNC machining centres to exploit the potential of 'large additive manufacturing' on thermoplastic materials. As a result, Genesi forms Breton's product range dedicated to the additive manufacturing industry.

Breton Genesi uses machine learning algorithms and advanced artificial intelligence systems to achieve high-level mechanical and aesthetic properties. It is one of the world's largest 3D printers for prototyping components at 3m high, up to 5m wide and length on request, with a deposition capacity of up to 200kg per hour of reinforced thermoplastic materials.

Genesi is available in additive-only versions or with the integration of milling capability on the same machining centre. The system is supplied fully-closed with a heated workbench for better temperature management of the part. The process predicts and monitors the correct layer adhesion temperature with thermal imaging cameras.



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