Apollo Exhaust Pipe

Project Story

Challenge

The biggest challenge was manufacturing a big, complex, enclosed titanium exhaust pipe as single-piece component without internal support structures , which would be difficult to remove. This requiresd close coordination of geometry, build strategy and process parameters to preserve the intended design while meeting functional requirements and ensuring repeatable production for all serial cars.

Approach

Serial small batch production smart generative design. project devided into stages, testing support free design concepts, producing samples for machining and surface finishing trials

Solution

3D printed titanium with beam shaping on a Farsoon XXL metal printer. Manufactured in Ti15. The "Dragon Skin" texture is integrated in the design and printed directly.

Outcome

An amazing piece of Art. A single-piece titanium exhaust pipe. Reducing welding, assembling and postprocessing requirements while preserving the intended design and adding the unique dragon texture. Demonstrating cost efficient sustainable production of a complex, low-volume automotive series