3d printing

Performance, Race

BBi R&D: 3D Scanning and Reverse Engineering with Creaform and 3D INFOTECH

Garbage in, garbage out as they say. Reverse engineering is part of every day development at BBi Autosport when creating new performance upgrades or bespoke components. Speed, accuracy and simplicity is key when it comes to gathering data as this helps shorten the development cycle and increase quality. We seek to have OEM like fit and finish with best possible performance possible within every part. For a lot of our development we are using laser scanners to collect data - which allow us to create 3D snapshots of cars and components. This way we do not need to keep referencing the vehicle.

Chris from 3D INFOTECH brought over the latest offering from Creaform - the HandySCAN Black. This is a simple hand-held scanner featuring blue laser technology which performs great on dark and reflective surfaces. The way these scanners collect data is by shining laser beam flashes onto surfaces and using special cameras to capture how the lasers bounce back. Small reflective dots allow the scanner software to create a coordinate system and align all the snapshots together - creating a larger 3D picture. The speed of capture, accuracy has been greatly improved with the HandySCAN Black as it was very impressive how fast it soaked up all the details. What is also very useful is that the objects that are being scanned do not need to be stationary. The 991.2 Carrera T exhaust that we were scanning could be picked up, rotated and moved (as long as the dots are still on) which allowed for much easier and quicker capture.

How that data is handled is just as important as the scanner hardware. Creaform has a great software package that reviews all scanned points, consolidates and optimizes the points and forms a clean, easy to manage file to be used in parametric modelling software.

These scanners allow us to reduce R&D time and reduce dependency on having the vehicle physically in-house for the duration of the development. The 3D snapshots of the parts and car allow us to work within a 3D environment, creating components that would perfectly mesh with the factory parts as needed.

We will update more as we keep developing the Porsche Carrera exhaust system, how we use the data and how our concepts come to life.

 

Performance, Race

BBi 997.2/991 DFI Intake Manifold Assembly

Rendering in Fusion360

Rendering in Fusion360

PN#: bbi.991.107.0005    

BBi has developed a comprehensive program for Porsche 997 and 991 DFI Turbo vehicles with full engine builds, big turbo systems with inconel manifolds, methanol injection systems, cooling upgrades and calibration. With every milestone we would develop new products and push the boundaries.

As the horsepower numbers climbed and as the need for E85 came around we had reached the fueling limit of the Porsche 997.2 and 991 Turbo DFI engines and needed a solution. Accommodating 6 more injectors required an intake manifold overhaul which presented an opportunity to resolve more bottlenecks.

997.2 and 991 9A1 engines were digitized with a Faro Edge CMM/Laser scanner and fully mapped. Porsche is very efficient with parts and engineering and we sought to do the same with this information to create components that are cross compatible. Processed data was then imported into Autodesk’s Fusion360 and overlaid.

IPD, a BBi partner, offers a line of plenums for the 997 and 991 platforms, and one in particular for the 997.1 Turbo, which features a large 82mm throttle body upgrade. We were able to evaluate the spacial constraints and incorporate the larger plenum into the design of the manifolds. As a result we are able to run the larger throttle body, gain volume and remove the restriction of the smaller OE DFI plenum. Having all components made of aluminum ensures reliability under high boost as well. The IPD plenum is modified to use Wiggins clamps instead of silicone hoses for maximum reliability and ease of installation.

Fuel injectors were modeled with the spray pattern and placed strategically within the runners, aimed directly at the back of the valves. The positioning ensures proper fuel atomization along with ample clearance for fuel rails, hardware and fuel lines.

The end result is an intake manifold configuration that has more volume, more fueling and more reliability for high boost applications.

The initial design was machined in house and validated on both a 997.2 and a 1200whp 991 turbo running 189 mph in the 1/2 mile with the capacity to hit 207mph. The system can support well over 1500whp with the right turbo sizing.

BBi has partnered with Pankl Racing Systems in to explore mass market applications for additive manufacturing. These low production volume, complex manifolds were the perfect product to leverage the high efficiency of metal 3D printing. The production units are 3D printed in aluminum and finish machined to ensure precision fitment and quality.

Engineering

  • 3D Scanned and CAD designed, Simulated

  • Optimized for 3D printing process

  • 6061-T6 Aluminum manifold and Fuel rails

  • 3D printed, CNC machined

 Features

  • CAD designed for volume, additional fueling and flow

  • Multi-Platform compatibility (plug and play for 997.2 and 991 Turbo Engines)

  • 6 additional injector ports so supplemental fueling

  • CNC machined fuel rails and mounting

  • Wiggins connections to plenum

  • Utilizes high volume IPD plenum

  • Utilizes larger 82mm throttle body