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Re:Porsche found a way to 3D-print lightweight pistons that ... by dkdk8283 on Monday July 13, 2020 @08:42PM (#23827354)
Seems like a nice PR piece. Porsche is using 3d printing to drive tooling development to cut new shapes on pistons. Awesome for r&d but 3d printing metallurgy has a long way to go before it’s production ready.

> and feature an integrated and closed cooling duct in the piston crown that's apparently unable to be reproduced using traditional manufacturing methods

Re:Porsche found a way to 3D-print lightweight pistons that ... by smaddox on Monday July 13, 2020 @08:58PM (#23827440)
SpaceX has been using 3D printed rocket nozzles with graded alloy compositions in production for years.
Re:Porsche found a way to 3D-print lightweight pistons that ... by DarthGhandi on Monday July 13, 2020 @09:55PM (#23827723)
Rocketlab too, additive metal manufacturing is definitely production ready.

There's YouTube channels that get 3d car engine parts printed. This is not just the realm of multinationals.

Re:Porsche found a way to 3D-print lightweight pistons that ... by stanfordkid on Monday July 13, 2020 @08:47PM (#23827384)
Surely they are innovating on the printing techniques themselves beyond off the shelf stuff (or having partnerships with the makers of the equipment).

If they can get the process reproducible and consistency up, I don't see why it couldn't be productionized

Re:Porsche found a way to 3D-print lightweight pistons that ... by abeppu on Monday July 13, 2020 @09:08PM (#23827497)
My limited understanding is that metal parts made by additive processes can end up with poorer lifespans than forged or machined parts. You get different layers which melted and cooled at different times, with weird residual stresses. Parts can fail sooner and just be weaker.

If your prototype only needs to live long enough for you to iterate on it, that might be great. But it might not be suitable for real world use for an extended period?

Re:Porsche found a way to 3D-print lightweight pistons that ... by g8oz on Monday July 13, 2020 @09:25PM (#23827582)
I’ve read that Rolls Royce is going to be using 3D metal printing on their upcoming Advance3 engine. If it’s good enough for those operating conditions then it should be good enough for anything.
Re:Porsche found a way to 3D-print lightweight pistons that ... by Swizec on Monday July 13, 2020 @09:15PM (#23827539)
Supercars aren’t exactly known for their reliability. I imagine Porsche would use this on their super and hyper cars first.
Re:Porsche found a way to 3D-print lightweight pistons that ... by thrwy_01 on Monday July 13, 2020 @10:07PM (#23827794)
Powdered metal camshaft lobes have been in wide use in production vehicles for several decades.
Re:Porsche found a way to 3D-print lightweight pistons that ... by culturestate on Monday July 13, 2020 @11:01PM (#23828028)
Powdered metal parts are everywhere today, but it's not really an additive process - you pour a bunch of powder into a mold, compact it, and then bake it.

PM parts are also porous and fairly weak (in some dimensions) relative to machined counterparts, so you don't typically see them in critical applications.

Re:Porsche found a way to 3D-print lightweight pistons that ... by ip26 on Tuesday July 14, 2020 @12:38AM (#23828574)
Yeah, now that you mention it, camshafts have quite a reputation for fragility. I always wondered how a rod of solid steel could fracture like that.
Re:Porsche found a way to 3D-print lightweight pistons that ... by mc32 on Monday July 13, 2020 @08:53PM (#23827418)
To add to that, by the time it’s ready for mass production, how important will piston engines be?

I suppose if will be gradual replacement by electrics but still it’s not like they would have lots of life in them.

Re:Porsche found a way to 3D-print lightweight pistons that ... by brownbat on Monday July 13, 2020 @09:18PM (#23827551)
Engineering Explained[0] on Youtube does a good job talking about improvements across both technologies.

He says he gets this question a lot when he talks about conventional engine improvements, whether or not they are going to be irrelevant soon. In one video (which I frustratingly I can't find at the moment) he lists a series of use cases that are going to rely on conventional, maybe diesel, for a long time, especially heavy hauls across remote areas.

https://www.youtube.com/channel/UClqhvGmHcvWL9w3R48t9QXQ

EDIT: This is probably the video: https://www.youtube.com/watch?v=Hatav_Rdnno&t=27s

Re:Porsche found a way to 3D-print lightweight pistons that ... by dpoochieni on Monday July 13, 2020 @08:56PM (#23827431)
Lol I'd say we still have about 50 years to go. Plus Porsche will cater to enthusiasts. I know I will always have at least 1 gas car
Re:Porsche found a way to 3D-print lightweight pistons that ... by toomuchtodo on Monday July 13, 2020 @08:59PM (#23827443)
https://en.wikipedia.org/wiki/Phase-out_of_fossil_fuel_vehic...

Scroll down to the countries starting to ban fossil fuel vehicles. I think you’re fine for the next 10-15 years, after that I think it’s hazy whether fossil fuel vehicles will be permitted to be used at all if battery electrics take off. My bet is we reach a tipping point and an outright ban around 2035, if not earlier due to refinery unprofitability due to volume declines.

I do look forward to Porsche attempting a competitive EV though!

@JumpCrisscross: Throttled, can’t reply to your comment. “Progress happens slowly, and then all of a sudden.”

Re:Porsche found a way to 3D-print lightweight pistons that ... by JumpCrisscross on Monday July 13, 2020 @09:04PM (#23827472)
> we reach a tipping point and an outright ban around 2035

Zero chance of this happening in the U.S., U.K. or Germany. I imagine the Gulf, India and China will similarly retain sport driving cultures.

Mass-manufactured ICE vehicles are past their nadir. But mechanical engines will have a long life thereafter.

Re:Porsche found a way to 3D-print lightweight pistons that ... by joshspankit on Monday July 13, 2020 @09:35PM (#23827620)
Based on what?

The minority may love the nostalgia, but sport racing cultures are primarily built on speed and ICE vehicles are already being left in the dust. Another 10 years and I would be surprised if there was a single ICE vehicle that could beat an electric.

Re:Porsche found a way to 3D-print lightweight pistons that ... by theluketaylor on Monday July 13, 2020 @09:48PM (#23827691)
There is some racing that lends itself to electric like stage rally, rally cross and the drag strip. I'd love to drive an electric rally cross car, especially since it's one of the most accessible forms of racing out there.

Circuit racing (in particular endurance racing) is a long way from electrics being competitive (though LMP1 cars certainly use a hybrid powertrain to boost speeds). Le Mans cars currently cover over 5000 km in 24 hours. When Porsche stretched the Taycan to the limit they managed 3300 km in 24 hours. That's roughly a 1950s Le Mans pace (and that as when the track had fewer turns and longer straights).

Re:Porsche found a way to 3D-print lightweight pistons that ... by nordsieck on Monday July 13, 2020 @09:52PM (#23827713)
> Another 10 years and I would be surprised if there was a single ICE vehicle that could beat an electric.

I think that really depends on the context.

For most races? You're probably right.

It'll be extremely difficult for electrics to beat gas cars at something like the 24 hours of Le Mans.

Re:Porsche found a way to 3D-print lightweight pistons that ... by joshspankit on Tuesday July 14, 2020 @01:46AM (#23828919)
I don’t see an inherent issue:

- Teslas are going to be built in such a way that every part runs for 1,000,000 miles

- “Refuelling” in the pit could be as quick as quick-releasing the battery sled, and popping in a charged one in it’s place

Re:Porsche found a way to 3D-print lightweight pistons that ... by theluketaylor on Tuesday July 14, 2020 @10:14AM (#23832194)
A million consumer miles is very different from 3000 endurance racing miles. It's not a coincidence Porsche is the most successful Le Mans team of all time and their cars can be absolutely beat on at the track without missing a step.

The FIA rules around 'refuelling' are incredibly strict and right now replacing batteries in the pit would be highly illegal. The rules can change of course, but with 400+ V and tons of mass that has to be slung around there is no way the FIA would take it lightly. When a couple extra seconds in the pit can make or break a race teams will always try to cut corners, so the FIA takes pit safety extremely seriously.

There is a reason formula-e used 2 cars rather than battery swapping when they didn't have the legs to complete a single race.

Re:Porsche found a way to 3D-print lightweight pistons that ... by joshspankit on Tuesday July 14, 2020 @10:59AM (#23832714)
> A million consumer miles is very different from 3000 endurance racing miles. It's not a coincidence Porsche is the most successful Le Mans team of all time and their cars can be absolutely beat on at the track without missing a step.

Definitely valid points here. I didn't mean to say that Tesla's million consumer miles meant that they could automatically endure Le Mans, but more that it's clear the technology scales very well. Maybe Porsche will come out of nowhere with an even more stable and more performant electric car that has a 6000mi range and can just hold the pedal down the whole time. Who knows, but my instinct says the eventual winner will definitely be electric.

Re:Porsche found a way to 3D-print lightweight pistons that ... by mc32 on Monday July 13, 2020 @09:37PM (#23827629)
Only thing I can think of is growl. Some people like that.
Re:Porsche found a way to 3D-print lightweight pistons that ... by userbinator on Monday July 13, 2020 @10:09PM (#23827804)
As someone whose daily driver has a throaty mildly-tuned V8, I can agree. ;-)
Re:Porsche found a way to 3D-print lightweight pistons that ... by joshspankit on Tuesday July 14, 2020 @01:42AM (#23828900)
Be easy enough to hook a speaker system to the acceleration
Re:Porsche found a way to 3D-print lightweight pistons that ... by Gibbon1 on Tuesday July 14, 2020 @01:56AM (#23828979)
I think they are already doing stuff like that.
Re:Porsche found a way to 3D-print lightweight pistons that ... by TylerE on Monday July 13, 2020 @09:50PM (#23827699)
The engine is very, very, rarely the limit in racecar performance. They're very tightly regulated.
Re:Porsche found a way to 3D-print lightweight pistons that ... by joshspankit on Tuesday July 14, 2020 @01:52AM (#23828957)
We’re talking engine and transmission at minimum.

Torque from an electric engine is insane. Tesla prototypes literally tore the transmissions apart. This is why a Tesla has the second fastest 0-60 time of 2.28 sec, and the low-end model (Model 3) still has a quick 3.0 sec time

Re:Porsche found a way to 3D-print lightweight pistons that ... by BoorishBears on Monday July 13, 2020 @09:50PM (#23827700)
We're rapidly reaching the limit of tire technology, not engines
Re:Porsche found a way to 3D-print lightweight pistons that ... by nordsieck on Monday July 13, 2020 @09:58PM (#23827736)
> We're rapidly reaching the limit of tire technology, not engines

Tesla is supposed to offer a "SpaceX package" with their Roadster that uses compressed air thrusters to overcome even that limit.

Re:Porsche found a way to 3D-print lightweight pistons that ... by BoorishBears on Monday July 13, 2020 @11:43PM (#23828292)
How? Unless the compressed air thruster is also going to take complete control over the cars handling... how is it going to overcome the limiting factor of the 4 contact patches your tires need to keep the car pointing in a given direction?
Re:Porsche found a way to 3D-print lightweight pistons that ... by nordsieck on Tuesday July 14, 2020 @01:53AM (#23828964)
> How? Unless the compressed air thruster is also going to take complete control over the cars handling... how is it going to overcome the limiting factor of the 4 contact patches your tires need to keep the car pointing in a given direction?

I guess we'll have to wait and see how it's implemented.

My understanding is that there are really only 2 times a hypercar is traction limited: accelerating from 0 and breaking. I suspect that those are going to be the only two times the system will kick in and have meaningful impact on the car's performance.

Re:Porsche found a way to 3D-print lightweight pistons that ... by BoorishBears on Tuesday July 14, 2020 @11:21AM (#23832969)
Even normal, 4 door cars with a little bit of power end up traction limited accelerating at speed

The system can only engage when the car isn't traction limited unless it's somehow taking the tires out of the equation for handling (which I doubt they're doing)

But the thing is, it's not going to be meaningful in any way. You can already get a car that would break traction at almost every gear (there's a 1000HP Honda Odyssey minivan by Bisimoto that needs it's power output limited per gear otherwise it'd just spin in place when you put down)

If the tires don't get better, you're not really able to use power past a certain point.

Things that matter more than raw power are stuff like suspension and weight. Things EVs do not do well with and end up relying on computers to make up for.

This is going to sound like the typical Luddite screeching about how computers ruin anything, but as someone who drives cars as a hobby and has built up a track focused roadster, it really is not the same experience driving a car that needs computers working overtime pulling power and adjusting each tire's speed individually vs a less powerful car that's just well put together and easy to control for mere mortals like myself.

Re:Porsche found a way to 3D-print lightweight pistons that ... by Normille on Tuesday July 14, 2020 @05:17AM (#23829945)
"breaking" != "braking"

No-one wants a car that 'breaks' when they press the pedal.

Re:Porsche found a way to 3D-print lightweight pistons that ... by Ericson2314 on Monday July 13, 2020 @10:14PM (#23827826)
s/nadir/zenith/, sorry
Re:Porsche found a way to 3D-print lightweight pistons that ... by swagonomixxx on Monday July 13, 2020 @09:15PM (#23827537)
I think diesel vehicles in metropolitan areas are the worst offenders.

Travelling around Europe, I think these were my biggest pet peeve, as an otherwise incredible and quaint city (such as Porto or Malaga) ends up being tainted with the disgusting smell of diesel fumes.

Petroleum only would be a huge improvement. Of course, electric only would even be better.

Re:Porsche found a way to 3D-print lightweight pistons that ... by elif on Monday July 13, 2020 @09:05PM (#23827478)
there is also a natural cliff where gas stations lose profitability. Considering many today only profit due to convenience store items, and consumer patterns have radically changed involving less random spending as well as less miles driven, this may be even sooner than we think.
Re:Porsche found a way to 3D-print lightweight pistons that ... by dpoochieni on Wednesday July 15, 2020 @03:10PM (#23850159)
Think it will become a matter of having enough money. Maybe it'll cost 10X more but as with all these kinds of policies and restrictions, $ will still speak. Since most of the bans you point to are about new cars, I can already bet that the price for used combustion engine cars will skyrocket depending on model. Hmmm, makes me wonder how one could play this market
Re:Porsche found a way to 3D-print lightweight pistons that ... by dahfizz on Monday July 13, 2020 @09:14PM (#23827528)
We still have 10+ years until batteries and charging infrastructure is good enough to completely replace ICE cars.

And then we have a few more decades while all the existing ICE cars age out and are actually replaced. Consider how many people today drive 10-20 year old cars. This goes doubly for high end collector cars like Porsches: Porsches from the 70s and 80s are still popular among enthusiasts, and these cars need to be repaired.

Re:Porsche found a way to 3D-print lightweight pistons that ... by HeadsUpHigh on Tuesday July 14, 2020 @05:36AM (#23830034)
I don't think the argument is about collectibles, people still ride horses and sail sailboats across oceans. At some point EVs will be cheaper to own than any ICE so even the old cars will get scrapped.
Re:Porsche found a way to 3D-print lightweight pistons that ... by funcDropShadow on Tuesday July 14, 2020 @09:31AM (#23831696)
But the question whether they really produce less pollution over their whole life time is still not settled. Production of the battery pack is quite energy intensive, lithium and neodym mining is not without problems. And you have to move around the battery pack all the time.

If electrical energy storage were the most economic one, I would expect at least one species to do that. Instead, they all store their energy in chemical storage mechanisms, i.e. fat, glycogen, ATP/ADP etc.

In order to solve the climate problems, it would be enough to synthesize gasoline from C02 in the athmosphere using renewable energy sources. A break through here, could immediately revert the whole trend towards electric vehicles. Of course this would not completely solve the pollution problem. Just CO2 pollution.

Re:Porsche found a way to 3D-print lightweight pistons that ... by HeadsUpHigh on Wednesday July 15, 2020 @06:20AM (#23843290)
It is 100% settled. This story about EVs producing more CO2 is a myth from an MIT study that was misinterpreted by a blog paid by an oil PR firm. And it seems to still be working despite the time that it has passed and despite the fact that the MIT team came forward debunking it. A Nissan Leaf for example takes 2 years to reach the breakeven point in CO2 production.