Researchers have managed to repair a broken clip on a car headlight using a 3D printer. This involved printing directly onto the existing headlight, which the researchers say is unique.
The test is part of the Repairbot project, a project conducted by Australia's Swinburne University in collaboration with the Innovative Manufacturing Cooperative Research Centre (IMCRC) and artificial intelligence-based and automated solutions manufacturer Tradiebot. The project is supported by automotive aftercare and accessories company AMA Group and the Australian federal government, among others.
Repairbot
The project was set up to help Australian bodyshops overcome challenges they face using technology. These include complex and restrictive design elements, wasted material and a shortage of workers with the right knowledge and skills. The parties hope that the knowledge they gain from the project can eventually be used in other sectors.
The Repairbot project includes work on a robotics and 3D printing technology that allows plastic components of cars to be cost-effectively repaired using additive manufacturing. This specifically involves parts that cannot currently be repaired and therefore need to be replaced. The project is also working on technology to rapidly digitise and analyse damaged car parts, and automatically generate a repair based on this.
3D printing system tested
The 3D printing system developed within the Repairbot project was recently tested, printing a replacement clamp for a headlight using a special material. This polypropylene composite material meets the stringent requirements of the automotive industry and can be printed simultaneously using a 3D printer. The material was developed by Dr Mostafa Nikzad, a materials scientist associated with Swinburne University.
During the recent test, the headlight was placed under a fixed print head and manipulated by a robotic arm. By moving the headlamp via a pre-programmed pattern, the material could be printed onto the headlamp in the desired shape to create a new clip. No supporting materials were required in this process. This is a significant advantage and, among other things, ensures that the printed clamp requires less finishing after the printing process, which reduces production time.
Repairs currently impossible
Mario Dimovski, founder of Tradiebot: "The Repairbot enables repairs to damaged plastic automotive parts that currently cannot be repaired. Not only do bodyshops and customers benefit, but also the environment as these damaged parts no longer end up in landfills. It's a win-win situation for everyone."
"The project, which will not be field deployed for another 18 months, now moves to the next phase for validating the material in real-world applications and fine-tuning the digital development of software to manage design and repair procedures," added Dave Calder, chief operations officer (COO) of AMA Group.
Author: Wouter Hoeffnagel
Source: Swinburne University
