Case StudyEngineering division uses 3D printed SLS technology to build full size dummy.
One of the main benefits ARRK offers clients is the wide range of productdevelopment services across the Group. One such example of an integrated
service offering, was the involvement in an automotive project for sistercompany ARRK Engineering. Although ARRK’s engineering headquarters isbased in Munich where it employs over 1000 people, it was engineers fromtheir site in Cluj-Napoca, Romania, who asked ARRK’s prototyping division tosupport them in development of a dummy using 3D printing.
The assembly was designed to help automotive manufacturers to evaluate
and measure passenger thermal comfort and environmental conditions. The
main body parts were to be fixed together with ball joints and angle joints
that are lockable in various positions, allowing for passenger movement andsimulation inside the vehicle. On the surface of the body panels, sensors tomeasure air temperature, air velocity, radiation and relative humidity werealso to be installed.
With these requirements in mind the engineering team needed a full size
dummy to be built, painted and assembled. Following various discussions,
CAD data was sent across to ARRK’s prototyping centre in Gloucester wheretwenty six components were built using ARRK’s Selective Laser Sintering
process in nylon glass filled material.
Parts ranged in size and complexity from the dummy’s head, torso, arms and hands, through to its legs
and feet. Numerous SLS parts also needed to be joined, assembled and re-enforced with glass fibre
matting to provide additional strength. The prototyping team were also required to source, manufacture

and incorporate over 60 CNC machined components in steel and aluminium. These parts also included
some welded fabrications, before being fitted inside the SLS parts by the Gloucester team.
Regular communication between the project designers in Romania and our prototype team ensured
parts were built to schedule and in line with the characteristics specified for each component. The
components were then put through ARRK’s in-house paint shop and colour matched to exact RAL
requirements.
The lead engineer on the project then visited the prototyping centre and, together with theUK team, assembled the whole dummy to ensure it all came together and worked asexpected. The dummy was later shipped to Munich, where it was to be fitted withvarious sensors and pressure pads ready for use.

3d Printing | Prototyping | Vac Casting | Mock -ups | cnc | rapid tooling

PROTOTYPING & MANUFACTURING SOLUTIONSCase Study

Glass fibre matting being applied inside SLS built parts alongside CNC machined, fabricated and welded components

Low volume SLS components ready for assembly

Paint & Finishing

Assembled sections

For further information on ARRK’s range of services, please contact:
ARRK Europe Ltd
Unit 11, Olympus Park, Quedgeley, Gloucester. GL2 4NF, UK
Tel: +44 (0)1452 727 700 Email: projects@arrkeurope.com

uk.arrk.com
3d Printing | Prototyping | Vac Casting | Mock -ups | cnc | rapid tooling

PROTOTYPING & MANUFACTURING SOLUTIONSARRK Europe Limited, a limited company registered in England and Wales with registered number 3418673.Its registered office is Caldwell Road, Nuneaton, Warwickshire, CV11 4NG, United Kingdom