[3D Printing Applications] Ford Motor Company: How to win the war on the production line?

[3D Printing Applications] Ford Motor Company: How to win the war on the production line?

Since its founding in 1914, Ford has been driving innovation in the automotive industry. From inventing the mobile assembly line (also known as "Fordism") 115 years ago to additive manufacturing today, Ford is committed to accelerating automobile production by improving productivity, ergonomics, and quality management.
While many companies are just beginning to explore 3D printing , Ford is already far ahead, reducing the time it takes for each vehicle to be completed off the production line.

Ford's experimental plant in Germany is responsible for pioneering the design of each new model; they have a complete small-scale production line and conduct years of development before mass production. Research and senior engineering teams continuously improve workflows, creating various jigs, tools, and specialized accessories.



Choosing the right 3D printing technology

In the process of vehicle production, many customized tools need to be designed for specific projects and development models; however, outsourcing customized tools is time-consuming and expensive. In order to obtain tools quickly, 3D printing has become a new production assistant for Ford Motor Company.

In addition to establishing a dedicated 3D printing team, they also adopted SLS ( laser powder sintering 3D printing technology ) for production. Since SLS technology requires post-processing to remove powder, Ford also began using the Ultimaker 3D printer with FFF technology, which can obtain 3D printed products more directly than SLS printing technology.



Because of its ease of use, from engineers to operators, the 3D printer can be used to create the tools they need. Ford stated, "We chose Ultimaker because of its excellent value for money, and we value its industrial-grade high quality and stability."

To improve oneself, one must first have the right tools.

Many manufacturing plants use 3D printing to improve the manufacturing process. However, by establishing a dedicated 3D printing workshop, Ford was able to confirm all design elements before new models entered mass production, giving engineers more time to design modifications or replacement tools. These specialized tools not only shorten production time but also cater to the ergonomics of employees, details that improve the smoothness of the production line.



Ford stated, "At the same time, the openness of the wires allows us to use industrial materials, which helps to create more durable tools and fixtures for mass production."



Global connectivity, local manufacturing

With the Ultimaker 3D printer , even non-technical personnel can 3D print the tools they need. Ford has introduced the Ultimaker 3D printer to factories across Europe, such as in Spain, Italy, and Romania. Designed electronic files are provided by a German design team, and through global connectivity and the Ultimaker 3D printer , these tools are immediately usable.



• Combine with software to lower the barrier to entry

Ford went a step further, using Trinckle's Paramate modeling software to allow employees without 3D design experience to create tool models; designs were sent directly to Cura slicing software and printed on - site using Ultimaker S5 . Currently, most engineers are still responsible for designing complex assistive devices; in the near future, even untrained employees will be able to use the software to create their own tools.





What are the additional benefits of 3D printing ?

So far, these new approaches have been highly beneficial for Ford; they have saved significant money and time compared to traditional manufacturing or outsourcing of custom tools. The Ford Focus uses only 50-odd custom design tools, fixtures, and fixtures, and further develops parts and components for the production line; these 3D-printed parts allow machines to operate continuously without interruption.



3D printing is not only economically beneficial, but many of its tools offer significant ergonomic advantages to Ford's manufacturing teams. Traditional metal tools become increasingly heavy after prolonged use, negatively impacting employee health over time. Ultimaker 's material properties are often sufficient to replace metal tools (further reading: The Mystery of 3D Printing to Lost-Waste Casting ) , making the assembly line work much easier for workers, as every second on the production line requires meticulous precision.

Looking to the future

Ford is rapidly expanding the possibilities of 3D printing . While improving processes and manufacturing aids, they hope that in the future, 3D printing will not only be used to manufacture tools, but also equipment and end parts. Beyond the automotive industry, 3D printing technology is also making progress in aerospace and medical technologies . (Further reading: Royal Netherlands Air Force: 3D Printing Technology Takes Flight! )

Technical sharing sessions connecting concepts to practice!

Want to learn more about 3D printing technology? SanDiMa will be hosting a 3D technology sharing session on December 21st (Friday)! In addition to learning about different 3D printing technologies and their applications, and seeing various samples, there will be hands-on operation of 3D printers (tutorial price originally over NT$3000) and an introduction to and application demonstration of the 3D software Autodesk Inventor (this session's theme: Achieving optimal design and extending it to manufacturing through Autodesk Inventor). Click here for details or to register directly !

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Original link: https://ultimaker.com/en/stories/52786-ford-reinventing-efficient-manufacturing-using-3d-printing?fbclid=IwAR0p6k2FTvJ8LzeZreMFoLwQlqGvatSse5QdzM6uJ5uZlsIxPPt5h2g-yAo