Gears that help transfer power from the actuator motor to electronic parking brakes in Audis, Bentleys and Bugattis are injection molded from Fortron linear polyphenylene sulfide (PPS). The electromechanical brakes are operated by a switch in the passenger compartment that activates actuators at the rear brake calipers. These brakes prevent a car from rolling on inclines as steep as 30 percent. They remain active until the car has enough forward speed not to roll back. The PPS spur gear within the actuator has a diameter of about 30 mm and is driven by a belt from an electric motor. The gear then drives a transmission that actuates the brake. The actuator housing is also made from an injection molded PPS body and cover. The housing size differs by car, but is generally 130 mm long, 50 mm wide and 80 mm high. The housing must withstand impact of stones propelled by tires and resists degradation from brake fluid and other chemicals used in cars. For more information on PPS gears, go to http://rbi.ims.ca/4933-519.
A new method of modeling how they are created with chemical vapor deposition (CVD) could reduce the cost of carbon nanostructures used for for research and commercial applications, including advanced sensors and batteries.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
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