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I hear you on the strength issues. Been thinking about it.
I’ve actually been using the core PPA from Siraya. It prints great. Later adhesion is better but still far from the material’s actual strength.
The one thing that I really don’t like is that a failure of the intake manifold could create a large vacuum leak which would be a lot like a stuck throttle. A small crack in the intake plumbing would be just be an inconvenience but a large crack after the throttle body is a safety issue.
It may be that I prototype with 3D printed PPA and then end up having it 3D printed in aluminum once it’s all sorted out. We’ll see.
I’ve been comparing my parts to the BMW M3 intercooler end tanks I have. They are pretty stout glass filled nylon but people run well over 20 psi boost on those cars. Pretty amazing what the plastic can handle. I’ll have roughly twice the wall thickness.
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