Designers used one of the most cost-effective and time-saving methods when designing the new 2014 Chevrolet Malibu: rapid prototyping also known as 3-D printing.
The process involves growing prototype parts out of powered or liquid resin at a fraction of the cost it usually takes to make test parts according to a GM press release.
Specifically designed laser sintering and stereo lithography help accelerate the vehicle's development and evaluation according to GM. Both processes use software, math data and digital lasers specifically designed for the Malibu, that would normally take days or weeks to accomplish in the past.
Click here for more information on the updates and rapid prototyping.
"When you need to get intricate, fully functional prototype parts quickly, nothing beats rapid prototyping," said Todd Pawlik, chief engineer, Chevrolet mid- and full-size cars. "Our ability to rapidly fabricate inexpensive prototype parts throughout a vehicle enables key components to get confirmed earlier so that we can go from computer models to production-caliber parts."
GM said 3-D printing allows designers and engineers alike to see, touch, and test versions of specific components and systems that will be used in vehicles in precise scale without having to make changes to production tooling.
Production tooling can cost hundreds of thousands of dollars according to GM.
Rapid prototyping was useful when making updates to the new vehicle's floor console, which features a pair of smartphone holders for the driver and front seat passenger. The console weighs less, which plays a role in the Malibu's improved fuel economy.
GM also used rapid prototyping to update the center stack trim and evaluate various surface treatments for the console and center stack, and re-sculpt the front seat back panels, located between seat frame and upholstery, for improved rear seat access and passenger comfort.
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