Redefining EV manufacturing with generative design and 3D printing [VIDEO]

Watch manufacturing innovation unfold in an end-to-end digital thread using advanced digital tools like generative design and 3D printing where Siemens has redefined what’s possible in next-generation components. A standout example? A high-performance EV transmission housing that’s 35% stronger and 25% quieter than traditional designs — an achievement made possible by digitally connecting tools for design, 3D printing, CNC machining, quality inspection, and assembly.

In the video below, we take you behind the scenes of this workflow, highlighting the role of generative design and 3D printing in creating the transmission housing. 

Leveraging generative design for superior results 

Generative design enables engineers to optimize components using NX Additive Manufacturing software. In the video, learn how Siemens experts applied topology optimization to refine the transmission housing’s structure, ensuring it could withstand operational loads while minimizing material usage. 

This is where we use all of these different additive tools like we covered in topology optimization and our conversion mixed modeling, as well as our setup and simulation tools to arrive at that first time, right print so that the customer has full confidence in that additive design.”

James Heckendorn, Pre-Sales Solutions Consultant, Siemens

This process begins with inputting data such as design constraints, material properties, and anticipated stresses. NX Additive Manufacturing integrated tools then simulate and generate the optimal design, producing a hybrid geometry that seamlessly integrates mesh and analytical data for further refinement. 

From design to manufacturing: a seamless workflow 

Once the optimized design is finalized, the workflow transitions to the manufacturing phase. Our experts used Siemens NX Additive Manufacturing to plan and simulate the 3D printing process. Key steps included: 

• Support Generation and Orientation: Ensuring the design’s printability by determining the optimal build orientation and generating support structures. 

• Simulating the Print Process: Predicting distortions and analyzing manufacturability to minimize errors and achieve a “first-time-right” print. 

• Compensating for Geometry Distortion: Adjusting designs based on simulation results to ensure precision during manufacturing. 

The final product 

By combining digital design, simulation, and advanced manufacturing, Siemens delivered a transmission housing that redefines performance for electric vehicles. This project demonstrates the power of digital manufacturing in reducing time-to-market and achieving unprecedented quality. Discover how NX Additive Manufacturing can transform your manufacturing processes.