The Digitally Optimized Turbo Manifold Collector | Rapid Prototyping Services
The Digitally Optimized Turbo Manifold Collector | Rapid Prototyping Services
The MTI team is excited to be providing their rapid prototyping services on a cutting-edge new project with Vancouver-based motorsports company, Extreme Turbo Systems. Extreme Turbo Systems (ETS) is known worldwide for their aftermarket performance automotive turbo kits designed to significantly increase the horsepower of a variety of automobiles. Their most significant achievement has been the development of worlds fastest Nissan GT-R.
The challenge from ETS was to combine their knowledge of performance automotive exhaust systems with MTI’s aerospace materials and manufacturing technology to create an optimized turbo exhaust collector that worked better than any other solution available in the market.
MTI began by examining how the current collector is produced and how it impacts performance. The complex collector is currently hand-made in stainless steel by the joining of a series of tubes by craftsman welders. The manual process takes several days to complete. The goal of MTI’s rapid prototyping services is to create an efficient, timely process. Upon obtaining success in this project, we will have cut out several steps in ETS’ process of creating a testable prototype – saving time, money, and resources.
A First Hand Look At Rapid Prototyping Services From MTI
 |
 |
|
. |
| Starting with the original collector, which fits with other assembly fixtures, MTI’s team of engineers and partners began to identify the best tools for taking a solid part and bringing it into a digital existence. |
|
. |
 |
 |
|
. |
| 3D Scanning technology was employed by MTI’s partner Peak Solutions to create a digitized point-cloud model, based on exact points of geometry from the part. The digital point cloud was then converted to .STL file and imported into SpaceClaim and converted to a parasolid format that would become our baseline for design improvements. |
|
. |
| Using the modeling capabilities of SpaceClaim, MTI and Peak Solutions created smooth transitions and surfaces to optimize airflow into the turbo from the collector. To test the concept the model was first printed in PLA-plastic for evaluation of Fit/Form/Function and Finish. |
|
. |
 |
 |
|
. |
| Next steps in the project will include flow bench testing of the plastic model, followed by further enhancements to the geometry. Final printing of the collector will be in 17-4 PH stainless steel which will be used for live engine testing on a dynamometer to prove real horsepower improvements. |
|
. |
 |
About Metal Technology (MTI)
With more than forty years of experience applying innovative, proprietary technologies, Metal Technology (MTI) is making possible the use of difficult alloys for a wider range of applications with greater efficiency, versatility, and reliability. Alloys include Tantalum, Niobium, Zirconium, Titanium, Tungsten and Molybdenum. MTI uses specialized deep-draw, spinning, forging, machining, EDM, and additive manufacturing methods to deliver superior products according to your exacting specifications.
Contact us for more information on our rapid prototyping services.
