Modeling and additive manufacturing of a scaled four cylinder petrol engine

In the automotive sectors, 3D printing has been used primarily for prototyping complex parts which offer the capability to produce shorter design iterations. 3D Printing is an additive manufacturing technique that deposits materials layer over layer to get precise components with lightweight, long-lasting, less cost, and shortened lead times. 3D printing methods may be used conveniently to produce complex shapes which have difficulty in conventional machining. The final product obtained from such process is identical to the original product and helpful in understanding the design parameters as well as to study the feasibility of assembly, working, and defects of various engine components. 3D printing is very economical to make a prototype engine model compared to a real-time model for the research and development stage. This work aims to develop a scaled four cylinder petrol engine model for design thinking by using CATIA V5 Software for modeling and Ultimaker 2 with Cura Software for 3D printing. The 3D printed engine model is light in weight, durable, occupies less space, less material cost, and can be easily relocated by bare hands from one place to another place for demonstration during teaching. This explores the opportunities of 3D printing in automotive sectors for spare parts manufacturing and rapid repairing of engine components as well.