The turbocharger volute is a critical component responsible for channeling exhaust gases to drive the turbine. It must endure extreme operating conditions, including high temperatures (up to 1050°C) and high-pressure environments (0.3–0.5 MPa). In motorsport applications in particular, volutes often feature highly complex geometries that pose significant challenges for conventional manufacturing methods such as precision investment casting, which involves long lead times and high tooling costs.
The adoption of 3D printed sacrificial patterns offers a compelling alternative, dramatically shortening development cycles and reducing mold expenses. This approach is especially advantageous for fabricating intricate internal flow channels-such as twisted cooling passages in turbo volutes or biomimetic gill inspired waterways in pump housings-greatly improving production yield and dimensional accuracy.
EXCELLENCE IN INNOVATION
Simons employs environmentally friendly 3D printing materials, including PMMA and violet wax, which minimize residue after burnout and help prevent casting defects. Furthermore, five axis CNC machining is used to precision machine flange surfaces and refine volute flow paths, ensuring high manufacturing efficiency and superior accuracy.
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