3D Printed Auto Parts—The Future Is Now

Overview

3D printing (also known as “additive manufacturing”) affords manufacturers the ability to create custom parts that fit together perfectly.  Utilized for decades in the medical products and aerospace parts industries, 3D printing is increasingly being used in other industries as well, including the relatively recent advent of 3D printed metal auto parts.

 New and Replacement Auto Parts

Automakers have made use of 3D printing processes since the late 1980s, with the initial output comprised primarily of plastic parts.  Manufacturers such as Ford, BMW, Bugatti, Chrysler, Honda, Toyota, among others, have embraced 3D printing in their research and development efforts, including the production of working prototypes.  While the automobile industry is currently unable to mass produce an all 3D printed vehicle, carmakers are already producing 3D printed parts, with the eventual goal, as soon as is feasible, of more fully integrating 3D printed parts into the original manufacture of future generations of automobiles.

Availing themselves of 3D printing processes for producing auto parts allows manufacturers to generate parts that are lightweight (which can improve fuel efficiency) and customizable, and that can be created quickly, enhancing the lean manufacturing focus on just in time inventory.  Although plastic has traditionally been the material most often used in printing parts, as advances in additive manufacturing have been made, so too has the use of alternative materials.

For instance, in 2018, French luxury automaker Bugatti announced that it had developed a new 3D printed titanium brake caliper prototype which, it claimed, was the largest functional titanium component produced with a 3D printer.  DS Automobiles, Citroen premium brand, has created 3D titanium printed parts for the ignition elements, as well as 3D printed titanium door handles, to give their DS 3 Dark Side edition vehicle a sleek, high tech feel.

Gas Usage In 3D Printing Process

To prevent corrosion, and to keep out impurities that can negatively impact the final product, 3D printed parts must be produced in an environment made free of oxygen, typically by the use of argon (and sometimes nitrogen) within the building chamber. That creates a stable printing environment, prevents fire hazards by keeping combustible dust inert, and controls thermal stress in order to reduce deformities.

Oxygen Monitors Can Improve Safety in Additive Manufacturing Processes

Dust from materials used in additive manufacturing, such as titanium, is, when exposed to oxygen, highly combustible and, therefore, requires monitoring to prevent possible explosions.Argon and nitrogen, while used in 3D printing for their oxygen depleting properties, require monitoring to ensure both the integrity of the finished part, and the safety of manufacturing personnel.

PureAire Monitors 

For quality control purposes, PureAire Monitoring Systems’ Air Check O2 0-1000ppm monitor has a remote sensor that can be placed directly within the printing build chamber, to continuously monitor the efficiency and purity of the O2 depleting gases (e.g. argon and nitrogen) used therein.

Moreover, to ensure employee safety, PureAire’s Oxygen Deficiency Monitors should be placed anywhere argon and nitrogen supply lines and storage tanks are located. In the event of an argon or nitrogen leak, a drop in oxygen will cause the built-in horn to sound and the lights to flash, thereby alerting employees to evacuate the area.  PureAire’s Oxygen Deficiency Monitors measure oxygen 24/7, with no time-consuming maintenance required. PureAire’s monitors feature long-lasting zirconium sensors, which are designed to give accurate readings, without calibration, for up to 10 years.

Winemaking - A Must Read

Background

The art and science of winemaking have been around for thousands of years. Winemakers rely on their instincts, palettes, and a thorough knowledge of the nuances involved in every stage of the winemaking process as they strive to achieve the flavors and qualities that they desire.Even a cursory overview of certain elements of the process underscores the critical role played by gases…from fermentation to first sip…in preserving the flavors created and nurtured by the winemaker’s skills.

From Harvesting to Fermentation

Since grapes do not continue to ripen after they have been picked, winemakers must carefully monitor the fruits when still on the vine, to ensure that they are harvested when flavor and ripeness are at peak levels. To protect the fragile grapevines, harvesting is typically done by hand, a laborious but important undertaking.

Once grapes are harvested, they are sorted and, sometimes, destemmed, and then crushed. At one time, grapes were crushed by hand (or, rather, by foot), but winemakers today crush them by using mechanical presses, which improves sanitation and the lifespan of the wine “must” (derived from the Latin phrase vinum mustum, or “young wine”), which is the industry term for the mixture of grape juice, seeds, and skins(and, in certain red wines, stems) that is the result of crushing.

The wine must is blanketed with nitrogen to reduce excessive levels of oxygen, which can oxidize the must, leaving it discolored and overly tart.For white wines, solids in the must are quickly removed after the crushing, in order to preserve the pale color of the juice.  For reds, solids are left in the must, to create a more flavorful wine.

Next, the young wine is transferred to fermentation tanks. The fermentation process begins when yeast is introduced to the must.  Most winemakers today use commercial yeasts, so they can control the predictability of the final product, though some winemakers (much like certain Belgian beermakers) continue to use the old-fashioned method of allowing wild yeasts to mix with the wine must. In either case, during fermentation, the yeast converts the grape sugars into alcohol. A byproduct of the fermentation process is carbon dioxide.  Too much carbon dioxide in the fermentation area can displace oxygen and create potential health and safety risks to employees.

The fermentation process can take anywhere from ten days to a month or more.  To maintain sweetness, some wines are not allowed to fully ferment, which leaves higher levels of sugar in the wine.

Once fermentation is complete, the wine is clarified or filtered, in order to remove residual solids and any other undesired particles. At that point, the fermented wine is transferred into aging vessels, most often either stainless-steel tanks or oak barrels.

Aging and Bottling

Exposure to oxygen can negatively impact a wine’s flavor, longevity, and overall quality. Inert gases, including argon, nitrogen, and carbon dioxide, may be used to flush oxygen out of the environment during storage, to help preserve the flavor and quality of the wine.

Flushing fermentation vessels, aging tanks, barrels, and bottles with an inert gas before filling with wine helps prevent oxidation, which is much dreaded by winemakers, as it produces discoloration, unpleasant aromas, and off flavors reminiscent of vinegar.

Oxygen Monitors Can Protect Winemakers and Their Employees

The same property--oxygen displacement --that makes inert gases ideal for winemaking, can be deadly if gas leaks from the supply lines or storage containers, or if there is a dangerous buildup of carbon dioxide during the fermentation stage. Employees could suffocate from breathing oxygen-deficient air and, since inert gases lack color, and odor, there is no way, absent appropriate monitoring, to determine if there has been a leak.

PureAire Monitors 

PureAire Monitoring Systems’ line of oxygen and dual oxygen/carbon dioxide monitors offer thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen levels for at-a-glance reading by employees, who derive peace of mind from the monitor’s presence and reliable performance.

Built with zirconium oxide sensor cells and non-dispersive infrared sensor (NDIR)cells, to ensure longevity, PureAire O2 and O2/CO2 monitors can last, trouble-free, for over 10 years under normal operating conditions.

As such, the use of PureAire’s monitors will enable winemakers, in a cost-effective manner, to preserve both the quality of their wines and the well-being of their employees.