Small series production of automotive parts, prototype construction, RIM processes

Small batch production

For our own projects as well as in customer service, we implement mold making for CFRP and RIM production in small series. We carry out the complete development process from the project idea to the final component. Depending on the requirements, the molds can be manufactured using a 3D printer or modern milling machines. The RevDop team accompanies you in the 3D scan and construction as well as in prototyping. Other projects can also be found on our Facebook page.

3D printing
oversize

The planned component to touch and test. As a specialist for 3D printing in the automotive industry, we support you in your product development in prototype construction. We also implement the prototypes for you in large sizes. Small series can be realized using 3D printing and the RIM process. There are barely any limits for the size of the components. Components with oversizes that exceed the installation space limits are cut into individual parts in CAD, 3D printed and then welded. This procedure is particularly helpful for body parts. The conventional development of body parts requires a lot of manual work. 3D printing of oversized components can save a large proportion of the very time-consuming manual work. The development of complex engine components, such as intake systems, is also noticeably optimized by 3D printing. By realizing oversized components, RevDop can also score with a lean development phase. The RevDop team has already proven this in the development of its own product range. Our business customers appreciate our quick implementation of oversize components at fair prices. The realization of oversized components through our in-house digital separation process with subsequent physical joining requires a high level of know-how in order to be able to maintain the required accuracy. RevDop is a specialist in this area and is a unique provider in this area with this self-developed process. Whether body or engine components. We are the right partner for high-quality and economical implementation.

3D print manufacturing processes

HP Multi Jet Fusion - This process uses PA 12 (polyamide 12). Compared to the laser sintering process, higher strengths, accuracies and resolutions are possible. In addition, printing can be done significantly faster, which is why the costs are usually the same or even lower. Jet Fusion components can be used as functional and finished components. In addition, depending on the component, quantities in the 4-digit range can be realized.

FFF process - The FDM process is particularly suitable as an inexpensive rapid prototype construction for design and installation tests (rapid prototyping). This process is often the method of choice, particularly in the development phase.

Innovative welding process

No size limits

Rapid Prototyping

We developed a prototype of a front spoiler for a BMW M2 Competition for a customer. Since a front spoiler with its dimensions represents an oversize and thus exceeds the build space requirements of most industrial 3D printers, the component was separated into individual parts in CAD and manufactured by 3D printers. Thanks to our welding process, which was specially developed for 3D printing parts in large sizes, the individual parts were joined to form a prototype. The spoiler has a very high accuracy of fit. When digitally separating the components, it is particularly important to take into account the specific processes of the 3D printing manufacturing process. Because there is great potential here to reduce process and material costs. For components with high volume ranges, the ideal filling parameters can be defined in sections. This ensures the perfect balance between the requirements of weight reduction and the stability of the component. Based on our experience, the implementation of oversizes with 3D printers can bring enormous advantages for the customer not only in terms of time, but also from an economic and technical point of view.

3D printing body panel

Tool form Carbon Hood Cover

We have made a mold for our RevDop BMW CARBON HOOD COVER F8 / F3 models. The tool mold for the production of a carbon hood cover of the current BMW M3 / M4 models was produced using the milling process. For this purpose, the hood was scanned with a 3D scan using a Romer measuring arm certified for the automotive industry. The resulting cloud of points was constructed into a CAD model using the reverse engineering process. This CAD model was the basis for the design engineering of the hood cover. The target design was implemented by our 3D scan and construction department. After prototype construction and the installation analyzes carried out, mold making was the next step. The tool mold is used to manufacture the bonnet cover in small series.

RIM tool front spoiler

The RIM process is also an important technology in small series production. In the RIM process, material components react chemically with one another. The result is a spread of the material in the mold. The tool is exposed to considerably lower pressures than, for example, in the injection molding process. This enables the use of plastic or silicone as tool material. This significantly reduces tool costs, which is why the RIM process is particularly well suited for the implementation of small series.

RIM-Werkzeug Luftfilterkasten

Luftfilterkästen sind sehr komplexe Bauteile. Manufacturing an air filter box in a small series using the injection molding process is generally uneconomical due to the enormous tool costs. The comparatively lower tool costs for the RIM process enable cost-effective implementation of complex components such as air filter boxes. In this way, geometries that are optimal in terms of flow technology can be realized at tolerable costs. We successfully use this process in the manufacture of our Toyota Supra air filter box.

Your professional partner for
Small batch production

Intelligent intake systems