Cassidy Silbernagel, a PhD student at the University of Nottingham’s Centre for Additive Manufacturing, was awarded first place in the student category of the Additive World Conference Design Challenge for a second year in a row. Building off previous success of winning the competition in 2016 with a redesigned electric motor housing, Cassidy’s carburettor design aimed at targeting more benefits of designing with additive manufacturing in mind.
The design incorporated moving parts, floats, an optimized design to reduce the number of support structures required for the build and utilised internal lightweight lattice structures generated using FLatt Pack – The Functional Lattice Package for Additive Manufacturing being developed by Added Scientific.
Cassidy's winning Carburettor from the Additive World Conference Design Challenege 2017, quater and full section. (Image courtesy of Additive World Confernce)
The judges remarked that the design showed a skilful combination of unique design characteristics achievable using additive manufacturing. The improved design included a swirling chamber to create turbulent flow to improve the mixing of fuel, a thin walled and hollowed choke plate to minimise weight, multi-angle fuel jetting for improved mixing of fuel, a removable fuel inlet to enable powder and support removal and a rough textured throttle plate to continue turbulent mixing. The triply periodic minimal surface double gyroid lattice reduces the weight of the component whilst providing adequate mechanical strength and performance.
FLatt Pack is being developed by Added Scientific as a part of the Functional Lattices for Automotive Components (FLAC) project which is funded by Innovate UK under the Office for Low Emission Vehicle (OLEV) framework. The project is in partnership with HiETA Technologies, Moog Controls, Alcon Components, Renishaw, and the Universities of Liverpool and Nottingham.
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