Enhanced Carburetor Performance through Additive Manufacturing

 

A competition go-kart team was facing difficulties in adapting a new carburetor version for their new engine type.

This new carburetor version caused the engine to sputter and perform slower than the previous season. Conversely, the older carburetor worked optimally with the engine but couldn’t be installed properly due to incompatibility with the new engine’s geometry.

Approach

First, Tenco reproduced the designs of the “improved” carburetor parts and adapted them to fit the new engine geometry. This prototype performed so well that a first series of 45 sets were produced and effectively implemented in the race, demonstrating significant improvements in both design iteration speed and performance.

Next, Tenco applied a production strategy, printing 20 parts in a single 6-hour job, which equates to 10 sets of 2 parts. This streamlined method facilitated the annual production of approximately 120 parts, each set of 2 parts.

Benefits

A significant reduction in lead times, slashing it by 2-4 weeks compared to traditional manufacturing methods.

Moreover, the material’s ability to withstand high-frequency engine stresses and its chemical resistance to petrol and oil underscored its reliability and contributed to enhanced operational efficiency over the long term.

Technique

DLP (Digital Light Processing) technology was chosen for this application because it meets essential requirements: high dimensional accuracy, effective liquid and gas tightness, shape stability, and strong chemical resistance. These attributes ensure the pressure gauge performs reliably in demanding environments.

And what challenge do you have in store for us?