Tests of a prototype for an ecological hybrid sports car with a classic car appearance, first presented in 2012, led to geometrical modifications to the gearbox housing. SICTA, based in Belfort, France, and a specialist in aluminum prototype castings, had already delivered the first gearbox housing (figure 1) for this very special car. The challenge was to ensure that the geometrical changes would not be critical for maintaining the good quality level already reached for the first prototype, and in the meantime the car maker also demanded a general cost reduction.
SICTA was the first company in Europe to have exclusively used 3D printed molds and has been using MAGMASOFT® since 2009 to develop their foundry processes. A first study of the gearbox housing casting had been made at the beginning of the project in 2012. Multiple versions had been simulated step by step and allowed SICTA to determine and to validate the rigging system and the pouring conditions. Specific data for 3D printed molds had been generated in 2015.