A new process used to update the Chevrolet Malibu for the 2014 model sounds more like the plot of a sci-fi movie than anything tied to designing cars.
To refresh the Malibu’s interior and exterior, Chevrolet designers used a process known as rapid
prototyping, which involves 3-D printing of parts.
The technology, as described in a Chevrolet press release, “literally” grows prototype parts out of powder or liquid resin at a fraction of the cost associated with building tools to make test parts.
Rapid prototyping, which uses processes officially known as selective laser sintering and stereo lithography, requires specialized software, math data and digital lasers, which accomplish in days what would have taken weeks of clay sculpting in the past, notes Chevrolet.
In a nutshell, it enables designers and engineers to more quickly build test versions of car components and systems that they can actually see, touch and feel in precise one-third scale and full-size models without having to make changes to production tooling, saving hundreds of thousands of dollars.
“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.”
On the Malibu, rapid prototyping was used to update the sedan’s new floor console (below), which now features a pair of integrated smartphone holders for the driver and passenger. The new console also weighs less, which helps contribute to the Malibu’s improved fuel economy over the previous model.
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