FCA US LLC is using 3-D printing to open a unique window on the world of axle development.
Conventional methods of evaluating oil flow inside axles and pinion carriers involve cutting windows into the components and then observing the fluid’s movement using a dynamometer. But with movement, oil turns milky and blocks the view afforded by two-dimensional windows.
So FCA US engineers decided to add a third dimension to the process by printing see-through plastic components exclusively for test purposes. This new technology allows correlation to virtual analysis of fluid flow.
As a result, the Company has a clearer view of axle durability and efficiency – and the road ahead.
“Efficient axles are critical to our powertrain strategy,” says Jeffrey Lux, Vice President-Transmission Powertrain. “For the customer, they offer an economical way to improve total powertrain efficiency. Accordingly, we’ve introduced six new axle families since the foundation for FCA US was established in 2009.”