Additive Manufacturing of Automotive parts which are LightweiGht and offer performanace Advantages over conventional Manufacturing (AMALGAM

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The aim of the AMALGAM project is to develop and demonstrate a revolutionary approach to the design andmanufacture of compound boosting systems, leading to improved engine efficiency and lower CO2 emissions.The new approach combines the latest hybrid laser cladding and 5-axis machining AM approach with partsproduced by powder bed fusion AM and conventional manufacturing in a single “join as you make” operation.This will provide a cost effective, efficient and flexible method of producing high performance automotiveparts, using the optimum combination of processes. The AMALGAM approach enables novel part design andmaterial combinations to be used which will have a dramatic impact on performance. The new approach is notrestricted to boosting systems but can be used in a wide range applications in motorsport, low volume andmainstream vehicles, as well as the wider high volume manufacturing sector.