At APR, part of our design process includes creating rapid prototypes we can physically hold in our hands, install on the cars, and check to make sure nothing interferes with the parts. We first start by modeling the engine bay and underside of the car using a FARO arm, and then our engineers use Pro Engineer to model parts. Before anything is ever cast, we create rapid prototypes with our SLA machine to ensure the design we have will actually fit and not hit anything we may have missed. This is especially important when we don't have direct hands on access to right hand drive vehicles in Australia, the UK and other countries as we can send the parts to our master importers such as APR Australia for installation into vehicles they have on site.
Once the green light is given, we can send the necessary parts off for tooling and eventually casting into hard parts we sell to you.
This is a pretty brief explanation of the process, and I've skipped a few steps, but mainly I wanted to show you a few cool photos of the SLA Process.
Once the design is created, it's sent to the SLA computer which essentially shoots a high powered laser into super expensive SLA liquid. This laser essentially hardens the liquid into the 3d shape we've modeled. In this case, we've modeled a turbo compressor cover. The entire turbocharger, manifold, oil lines, coolant lines, exhaust, intake and outlet hoses are modeled and will go in next.
Here's the laser in action:
The next morning, out cames the hard part. This design is modeled mainly for external void. Holes were modeled into inner design to easily drain out excess liquid and to make it easy to remove support pieces.
The final process includes cooking the piece in a UV light chamber. This process basically looks like a small scale tanning bed.
As more parts are completed, I'll revisit this thread with images. :-)
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