Rapid manufacturing promises customised cars built to order

DRIVERS may soon be able to have parts of the family car built to their own design through a local dealer as a result of advanced rapid manufacturing systems being developed by a consortium of UK engineers.

The new rapid manufacturing (RM) machines are expected to be the product of a Foresight Vehicle initiative, involving more than 400 companies and universities.

The idea of such machines is to allow seats, steering wheels, gear knobs and handbrakes to be built to the exact individual requirements of car buyers. Seats designed to a person’s exact profile would increase comfort, reduce driver fatigue and improve safety. Dashboard inserts such as air ducts could also be designed by drivers and built to order at their local dealership to match their particular preference.

The 3D profile of the client would be scanned at a dealership equipped with the RM machines now being developed at Loughborough University. These machines will build up the components in a layering technique similar to the way inkjet printers make images.

The new machines would be designed to be free of the complexities of a full-size car factory. Instead, they will be engineered to operate in small workshops. Similar technology is already used by Formula One motor racing teams and in some specialist aerospace operations.

The head of the Loughborough University research group, Dr Richard Hague, said RM will have a significant impact on the future of the automotive industry.

“The need to meet the demand for personalised products, particularly within the automotive sector, is growing increasingly important,” Hague said.

“Rapid manufacturing offers the solution and benefits all parties involved. It is essential to embrace the technology offered by rapid manufacturing and maximise its potential to develop the future of automotive manufacturing.

“When fully developed, this type of system will help industry win back some of the business that is being lost to places like India and China.”

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