3D Printed Aluminum Intake Manifold - Laser Melting Process
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- Опубликовано: 3 дек 2019
- We needed an intake manifold made quickly so we used the most modern manufacturing technique and want to share the process.
Folks who printed our part: www.mimotechnik.com/
Check out the full 1000 Horsepower 2020 Supra engine build:
Episode 1 - The Teardown: • 2020 Supra B58 Engine ...
Episode 2 - 1,000 HP engine parts: • The Making of 1,000 Ho...
Episode 3 - Engine Assembly - Start to Finish • 2020 Supra 1000 HP Eng...
Episode 4 - Dyno Test: • B58 Engine Dyno 1000+ ...
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ABOUT PAPADAKIS RACING:
The Papadakis Racing team began drifting in 2004 and is the most winning team in Formula Drift history, earning the 2015 title with driver Fredric Aasbo, as well as backto back championship titles with driver Tanner Foust in 2007 and 2008. The Rockstar Energy Drink / Nexen Tire Toyota Corolla Hatchback is the latest competition build from the Hawthorne, California, based team.
Team owner Stephan Papadakis is a legend of sport compact racing who began building his reputation in the 1990s with the first front-wheel drive, tube-chassis drag car in the U.S. The team earned multiple records and championships in the discipline, turning in elapsed times and trap speeds previously thought unattainable in front-drive drag cars. Papadakis' successes in front-wheel drive were matched by his efforts in rear-wheel drive when he campaigned a Honda Civic that became just the fifth car to join the NHRA's Sport Compact 200 MPH club 
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How much does it cost? About $800 per pound. So a 10 LB part would cost $8,000! What would you want to print out of metal?
PapadakisRacing a personality
It would be cool to print custom/reproduction car badges. Custom printed shift knobs could be interesting.
Replica Dardick trounds.
What the manifold weigh?
A reproduction of the GReddy MP90 supercharger kit for the 3UZ
Str8 to the point no "fat trim" needed. Great content.
I love this channel for this-- very direct with the information, yup.
I second this! great detail and to the point
Step 1 : buy 3d printer
Step 2 : print 3d printer
Step 3 : return 3d printer
Well I mean it's entirely possible to do it as people already print their own ones minus circuit boards and stepper motors etc.. crazy haha
Enjoyed this comment, thanks. :) Also it's funny because it is somewhat true.
Black hole can be opened...
Step 4 : skynet has become self aware
@@eedesign878 Not just somewhat, it's called RepRap, google Prusa Mk 3. Got one at home
Your content is fantastic. Thank you so much for always being so concise and to the point. I find myself rewatching portions rather than skipping ahead like so many other videos.
Such a good use of aluminum. Glad to see how far technology has come.
That’s an “older” printer too they are getting really good really fast
@Kevin Schmidt can be done with any metal. titanium especially, because its so hard to machine or form, and an expensive materia to waste so much during subtractive manufacturing. its getting to the point where its gonna be cheaper to 3d print titanium and other exotic metals, rather than create a part out of billet via subtractive manufacturing
Kevin Schmidt It’s basically just Percision welding so if the medium (powder) is available they can print it.
There's MarkForged, they use a different system and seems way faster and simpler than this.
@Kevin Schmidt yes, for example markforged can print in a lot of different metals. Crazy stuff!
[And no, I'm in no way affiliated with markforged, just like what they do]
It’s easier to do it the old fashioned way sometimes haha all this new stuff is getting complicated 😂😂😂
koenigsegg has been printing some of the more exotic metals for a while now but im pretty sure in a different process. its rad to see this shit evolve!
Man this is so awesome, thanks for providing a video on this.
I just love how much knowledge you guys drop on us regular people, pretty awesome !!
haha Very true. Back in the day you had to be cool enough or lucky enough to be around such people but now RUclips lets everyone in!!
Yeah, well, kinda.
Most shows on youtube that are supposedly scientific basically don't tell you shit. Steph at least shows you the whole process of the build, which is great, but he doesn't show you the designs process, calculations, tuning, etc. The good thing is that this kind of content is understandable for everyone (even outsiders to tuning) and it's still nice to watch even if you're into tuning yourself. This is valuable content, I like it. But still I think he isn't sharing a lot of knowledge with us in terms of specific details. Why? Because I have seen how generously Russian youtubers share their knowledge. _"So I have ported the intake to 26mm diameter, at the valve guides it's 27mm, where the ports come together it's ported to 37mm, I only polished the top side because the bottom side has will have slow separation and therefore a rough surface is preferred"_
I love also, he is just as happy to show hid mistakes, as well as his sucess. Super easy to learn from such a wizard!
@@sasjadevries Why would he share detailed knowledge? It's an important part of his business and he would lose money by doing so
@@kiyoponnn It depends on your business model. And sharing info actually makes a ton of sense in quite some cases.
If you are open and honest about your setup, then most people will think: _"hey, looks like you know what ya doing, can you tune my car"._ Such a honest approach and open attitude can bring in a lot of customers.
In practise it's the charlatans and noobs who don't want anyone to see how they get their job done, because they're bad at it.
And then there is the difference between knowing what should be done and actually having talent doing it. Telling someone how it should be done doesn't mean he will succeed.
One great example of this in autosports is "Gocha", from the beginning of his career he has been sharing info about his setup _(including precise camber angles)_ with anyone that's interested, dozens of engineers from Europe and Japan have examined and photographed his car; and guess what: he became drifting world champion *again* in 2019.
G.M. has been 3D printing of prototype intake manifolds since the 1980s.
At that time I was an instructor at a local college and G.M. donated what was then called a stereo - lithography machine to the college.
The media was a resin compound but worked well for prototyping low stress components.
Love that 3D printing has come this far, almost mind blowing that we're able to do this
It’s amazing how far we have come with technology.
I've been watching and trying to understand how Metal 3D printing works and your video made sense to me finally. This simple breakdown of all the parts and events made perfect sense to me. What a great video!!!
I am so amazed at this kind of technology and this whole build that by the time the video ends I realize my my jaw has dropped and I need to close my mouth! So awesome! One of the many professional paths I wish I would have chosen!
Love love love these videos. Wish this one was 10x longer though! Frigging amazing technology....amazing what can be done today with 3D printing.
Also can be done in 1 hour with a weld and some pipes
An hr is a bit short for a custom part... Though this is not going to be its typical application... some of the aerospace stuff with titanium is stupid strong and you can do much more complicated inner shapes that are hard to replicate otherwise...
Question is, What uses more energy and time, casting or printing?, and long term reliability? just a thought. Unbeatable for prototyping no doubt.
@Brad Viviviyal Why is it stronger?
@@samward2162 Cause the laser makes the grain structure of the metal jumble. Casting nowadays is done efficiently and doesn't have the same problems that it did back in the day. Hopefully 3d printing metal gets better.
@@walangchahangyelingden8252 3D laser sittering have more compacity than casting today, so it's mechanicaly better than casting
@@surronzak8154 Still weaker than casting.
@مبغض الظلمة 100%
This channel is PHENOMENAL!!! So concise, easy to understand, and interesting content!
This is a very well-edited video. I really appreciate that you keep everything short, to the point, but still take the time to explain everything.
Papadakis I appreciate your content. I’m always happy to come to your channel to learn something new. You highkey inspire me to learn more about Material Engineering as well Mechanical. RUclips channels like yours and SpeedKar99 are how I spend my free time. Thank you so much.
I echo this statement. Was telling wife how appreciative I am of content like this and that it will be here forever to teach future generations. The gift that keeps on giving
2003: yOu WoUlDn'T doWnlOaD a CaR!
2019: This car is the wrong the color - is the magenta toner out again?
Yes, why is the Magenta always empty when you never print anything Magenta?
PC load Letter....WTF does that mean?!
Error: Please change Tray 1 metal.
Set Aluminum 6061, Fine Powder.
Press [Details] button for help.
good of you to make this vid. it lets us keep up with this new technology
This is one of those times when technology is absolutely amazing! Great stuff. Cheers fellas.
Fricken laser beams! Jokes aside that is an incredible process.
at first I was super pissed at your comment but then you said jokes aside so now I feel neutral again
i read that in dr evil voice hahahahahah
Super cool! Next step is a 3D printing of an already tuned supra :)
Yes we will wait for the Supra racing car to be totally reliable then scan it and print it :-) in multiple materials for each component.
actually there are 3D printed connecting rods :)
This series is so good. Awesome to see the automotive corner of RUclips continuously progressing
Papadakis Racing - Best channel on RUclips. Thanks for the great vids Steph.
If they ever come up with a high-speed version of this idea, say ten minutes per part, it'll revolutionize manufacturing as well as make it possible to keep any antique vehicle on the road.
Thanks PR for sharing your awesome video.
Your quality of work is superior, you guys have set the bar on 2020 GR supra to another level.
Looking forward to your next video
Awesomeness at its finest, keep up the wonderful work that you do extracting horsepower where there was limited or restricted. Have a great day.
" Its a fairly simple process, you just take this giant laser and shoot it at powdered aluminum! Easy, right?"
@Lassi Kinnunen or investment casting like Jay Leno has done in the past to make some of his parts
aniruddha patil what do you mean crashes at 90%?
@Lassi Kinnunen your first paragraph negates your last paragraph. Replacing pla with aluminium via casting reproduces the EXACT same shape as the pla part. If you printed it, you can cast it.
Casting is easy
@Lassi Kinnunen but unfortunately aluminum does odd things when being cast into large and/or complex shapes. Would probably take several attempts to get the venting, sprues, and runners right. It's not always as easy as one might think.
My favorite part about 3d printing is that you can make complex parts with perfect fitment
@@RazgrizDuTTA fitment under the hood of the car
Am new in 3d printing may u advice on how I can retrieve exact size of a car part I wanna print and may give me a link if u dont i want to start an aftermarket busines in south africa
It’s always so great watching new tech. Especially since I’ve been following you and your career since the 1990’s.
I find this utterly fascinating from a technical perspective.
The ability to produce parts in this way will only be improved and refined as time goes by.
Likewise, I expect new processes will come into being as new machines are developed.
Thank you for this highly interesting and informative insight into printing components. Subscribed.
Printers with freaken laser beams on their heads!
Not sure if this was just an Austin Powers reference or if you really knew and was being ultra clever, but the unit that lays down the medium (whether metal or ink) is referred to as a print HEAD.
They sent a small version of this to the ISS... Mind Blowing thought....
This is basically a Star Trek REPLICATOR!
this is actually a great way to give an even more prolonged life to old cars, make 3d print parts and then cast them into iron or aluminum or even steel
Papadakis you are from Greece ,I am feel happy to seeing what awesome projects you works
I really want his opinion on tb48 engines , specially those modified in UAE
Fun fact: I’m currently working on a project at my university that’s looking at speeding up the build time of those 3D printers by increasing the thickness of each layer. The only issue is that increasing the layer thickness could introduce porosity which would lead to mechanical deficiencies. It’s really cool and I’m really happy with the exposure this kind of printing has been getting recently.
The other issue is that increasing the layer thickness reduces your Z-axis resolution. It also slows down the process because you need to scan the laser more slowly to melt the increased volume.
In ceramic shell , some times we got porosity . You have so much time in the part , you try and save it . You can paint the runners inside with Devcon Liquid Aluminum Epoxy , never had a problem with it coming off , if applied to a new part .
that's really UNIQUE content about autosport, please bring more of this!
Stereolithography. Been doing plastics like that since 1986. That was even more complex: The laser focus was fixed right above the pool of resin and a bed would break the surface and get lased wherever it needed a build up. then it would lower 2-3mm and rise up again (minus the height of 1 layer) with a fresh layer of resin on top of the last layer...lase that layer...on and on and the machine would have to wait for any waves to stop in the tank so it was an overnight process for a few inches but you could build a furnished doll house a layer at a time. Now they are doing it with aluminum powder. That is some one off stuff right there as the cost to 3D print a form for a custom AL casting would be cheaper and maybe just as fast if you had the production nearby waiting for the part.
I feel like technology has advanced 50 years in the last 10 years
Aliens man.....aliens
Lots of Patents have expired
this technology is at least 15 yrs old
this is 80s tech Lol
In 1976 A genius was born. Wrote the screenplay for Star Wars A few months later. It included music, designs of things like the Death Star, Millennium Falcon Etc.
Most of the popular movies/T.V. series since are his.
Apple, Tesla, Microsoft, videogame industry, Lockheed Martin, Ford, Toyota, Honda, Mazda, GM, Ferrari, Lamborghini, Keoningsegg, Pagani, Bugatti and many other companies have received his help.
Currently has an anti-knock prototype that lets you advance ignition timing to most I.C.E.
Can make his own drugs/medicine with the greatest of ease.
With many other projects not being mentioned, are in the works.
Pap the Aliens called, said they want their technology back.
thanks for the no-nonsense approach to the video.
Thank you for sharing the amazing projects you get to work on, and the technology you get to work with!
Im impressed with a ink printer. Imagine how impressed I am with this... lol
Lol
*an
We live in a world where we can 3D print things out of metal, yet the jury is still out on what a woman is. Mind boggling.
best comment
heres your trophy
🏆
Steph is the no-nonsense King of engine building content.
The only thing I can say is WOW. This 3d printed part from aluminum powder is awesome. Great job
Yeah, sure the cost is high and the process is slow but imagine where this process will be 10-15 years...
This technology is already 20 years old.
more like 1-1.5 years
more than 20 years
designandmotion.net/design-2/manufacturing-design/dmls-a-little-history/
It was by 1980 - I remember because I was working in the business hub of Toronto for a mining company that makes fine metal powders like nickel and cobalt for tech leaders like GE's jet engine division. In our office tower there was an architectural firm that was modeling proposed projects, i.e. those miniatures of office towers you'd see in lobbies. They had something that would lay a non-metallic powder and follow that with an adhesive to bond it where desired, then go up a level and repeat, etc. I thought it was a nutty way to make a model but who's to judge.
That would be the grand daddy inception of powder deposition.
Early 90's I paid $625 for a Creative Labs 3X speed CD writer to be able to tell customers we could burn CDs for them. Slow as molasses but the first on the block. I paid over $300 for my first DVD burner a few years later (~1995) and it wasn't even 5X write speed.
Casting iron technology is about 2400 years old, so you could say it took quite a while to get to todays casting quality. So relative to that 3D metal printing technology and quality is developing/progressing pretteh fast!
Technology is getting close to science fiction.
SiFy Up your GAME LOOL
That is so freaking cool!!! Thanks for sharing! I love seeing how tech like this works!
Some excellent content and nice insight into future tech!!
2:40 Why does it look so disturbing to me ?
It's called trypophobia.
I know what you mean. With CNC it's easy to forget how to read a regular micrometer. A young friend of mine found a slide rule in one of my tool boxes and asked me what it was used to measure. I told him it was a calculator. He still doesn't believe me.
@@mactastic144 Cheers. That explains a lot to me. Thought i was only one.
Not only is it weaker it also cost 10x more. what an innovatoin.
What is your evidence that it's weaker? SLS metal parts are similar in strength to billet. They're weaker than forged, but the process is much cheaper than forging and allows for significantly higher design complexity without an increase in cost. Sounds like you're pulling things out your ass to me.
@@Tristor86 first off cast parts are way cheaper then 3d printed. like WAY cheaper. and billet is way strong then cast or 3d printed. do you get all of your knoledge from rediulous youtube videos like this one?
michael provost: I’m an engineer and I fabricate parts for race cars. I know a thing or two, as does Papadakis Racing. Where are you getting your information about the strength of SLS? It’s not as strong as billet, but very close, and allows significantly more complex designs to be produced which is an acceptable trade off to improve packaging and efficiency.
@@Tristor86 if i hit a piece of billet aluminum with a hammer its going to dent a little, if i hit a piece of that with a hammer it breaks. yea you can make complex designs with it. that is the only advantage. maybe another 10 or 20 years the technology will catch up to the hype.
michael provost: You’re making claims not in evidence. What you said is not an accurate statement. I don’t have anymore time to waste replying to you. You don’t know what you’re talking about.
I feel so lucky to have insight into engine building this advanced.
I LOVE your videos - best technical car content on the Internet! 👍
$10K later and we have a converted direct injection to port injection setup.
Hopefully they run both like newer Coyote engines
@@dhodg777 Looking at the dyno vid the direct injection didn't work out so well.
@@mrred1012 they did not use direct injection so injectors had no fuel flow = no cooling so they just melt and burn out, thats why its hard to install a LPG to direct injected engines
@Clifton Green that's really besides the point. I merely meant that it could be spent on upgraded direct injection technology. Which is going to be the future anyways. The only current obstacle is cleaning of the valves that port injection offers.
@Clifton Green he already dyno the engine with only port injection and direct injectors literally get burnt out, check he's other videos
I can’t wait when Walmart sells that printer for 99$
Russian Bot why would you want a piece of shit printer when there would be better high end 4D printers available by that time?
Shity tool = shity job!
This is incredible! I feel as though NASA has started tuning supras. The cleanliness of the shop and thorough operations set these guys high atop their competition.
God I love these videos! No waffling, no bullshit, just knowledge bombs.
Yeah, there's no way having that printed in wax then doing a basic cast would be cheaper or quicker.
I'm scratching my head on why supports were needed at all? SLS is inherently self-supporting.
SLS is not self-supporting for metal. Just another reason this should have been done with RapidNylon.com
It's not really, the wiper pushes the powder down as it travels and may dislodge bits of the build
This thing it's absolutely amazing.
Quality is always on point
Welcome to the Future 😳
Advance Aliens: Hold my beer. Well mold material out of atoms and energy into the 5D
amazing i would like to see more of this 3D printed metal and the actual engine test. Thanks!
This is the coolest thing I have ever seen
$8k for ten pounds! I wanna know how much it cost to build this 1000hp engine, amazing!
The manifold is a prototype, so it'll always be really expensive.
In the future, when something breaks, people will go to the printing Shop next to them and not the parts store.
Everyone will have one, just like a flat screen tv, or microwave.
It's way cheaper to just produce a few 1000 extra parts, and sell them, rather than printing every replacement part. Plus, as you saw in this video, they aren't ready to go out of the printer, they still need some machining.
Actually this will just decrease the cost of production. You will still be buying parts, they will just be cheaper.
Surely you're not suggesting that someone could blow the welds on an intake manifold?
Impressive! I once interviewed for a company in Michigan that build parts using ultrasonic welding. The base material was a metal tape, I forgot what alloy. Around 2007.
The Very Best RUclips Channel Engine Buildup and Teardown of the Whole of the Internet.....
I am missing the point as you could have made a STRONGER carbon fiber manifold for less money as saved a lot of weight. Who decided to do this?
Susan.
Careful you don't blow the welds on that intake manifold or you will owe me a 10second car.
Always so educational and interesting. Thanks steph and team!
Amazing video as always
Did anyone else at first glance think why would they 3D printed the welds? Haha
That was my question... since it was CAD designed, and printed in .002" layers, why are there obvious tig welded seams around it?
It was printed in separate pieces then welded together. Probably limited to size of printer or to guarantee perfect fitment.
"Typically they wear respirators because the aluminum is so small and dangerous"
JustWasted3HoursHere lmao I was seriously thinking the same thing aha.
Custom tools, drill guide! Awesome. I couldn't imagine having the capability to create my own tools
Sometimes depending on the part, there are high internal stresses and parts can warp when taken off the build platform. Fantastic process, but more suited to complex form designed specifically for the application. Conformal cooling channels in tooling inserts are a good example.
again i commend and thank you for going so in depth in technical videos. the more information we all share the faster we all grow!
Loving the content Steph!
Happy holidays
Wow, I have huge respect for your knowledge and capabilities. You are right up my alley as far as the quest for engine building and design knowledge through all types of racing and all types of engines. 1000bhp is a very impressive number for a production based motor. The only itch I have is with the amount of money that is invested to obtain these results. I am sure that with the considerable resources put at your disposal, similar results could be had with a lot of other production based engines from different manufacturers which sort of takes away some of the glory that Toyota or BMW would like to earn as a result of this build. With that being said, I will continue watching your videos with great admiration. Thank you.
Inspirational! Thank you for the excellent, up to date content!
It couldn't be better. Amazing.! thanks for sharing!
Layer by layer. Very interesting. I was picturing liquified aluminum being squirted from a single tip. Now I see how it can work.
Now that is just sick!! 3D printing tech is awesome.
Can’t wait to see the motor back in the Supra.👍🏽👊🏽
Awesome.... Unlimited application... So we can literally make everything bespoke - if we have the money - now...
Love what you teach and share
Wow that's eye opening tech and engineering stuff.
Really enjoy your videos!!!
I absolutely love what you do! you're a big inspiration.
John Cohen is such a great guy, glad y’all were able to work together
When you post a video, that's definitely priority for me to watch!
This is really top notch content.
Papa doing some good work!
Brilliant technology. Have a nice day all. CHEERS from AUSTRALIA.
Amazing ! can make insane shape with this printing technic
I totally want like a dozen Parts made in this machine for my L28et but I'm sure they would want some ridiculous amount of money. Super exciting to see technology come along maybe someday normal people can afford them.