Since its establishment in 1914, Ford has been driving innovation in the automotive manufacturing industry. From the invention of the moving assembly line (also known as "Fordism") 115 years ago to today's additive manufacturing, Ford is committed to improving productivity, ergonomics, and quality management to accelerate automotive manufacturing.
Many companies are just beginning to explore 3D printing, but Ford is already far ahead, shortening the time it takes for each car to be completed on the production line.
Ford's experimental factory in Germany is responsible for pioneering the design of each new car model; they have a complete small-scale production line and conduct several years of development before mass production. The research and advanced engineering teams continuously improve workflows, producing various jigs, tools, and specialized auxiliary tools.
．Choosing the Right 3D Printing Technology
In the process of vehicle production, many custom tools need to be designed for specific projects and development models; however, outsourcing custom tools is time-consuming and expensive. To quickly obtain tools, 3D printing has become a new production assistant for Ford Motor Company.
Not only did they establish a dedicated 3D printing team, but they also adopted SLS (Selective Laser Sintering 3D printing technology) for manufacturing. Since SLS technology requires post-processing to remove powder, Ford also began to use FFF technology Ultimaker 3D printers. Compared to SLS printing technology, it allows for more direct acquisition of 3D printed products.
Due to ease of operation, both engineers and operators can use 3D printers to produce the tools they need. Ford states: "We chose Ultimaker because of its excellent cost-effectiveness. We value its industrial-grade high quality and stability."
．To do good work, one must first sharpen one's tools
Many manufacturing plants use 3D printing to improve manufacturing processes. However, by establishing a dedicated 3D printing studio, Ford can verify all design elements before new car models enter mass production, giving engineers more time to modify or replace tool designs. These special tools not only shorten production time but also focus on employee ergonomics, and these details improve the fluidity of the production line.
Ford Motor Company states: "At the same time, the openness of the filaments allows us to use industrial materials, which helps in making more durable tools and fixtures for mass production."
．Global Connection, Local Manufacturing
With Ultimaker 3D printers, non-technical personnel can also 3D print the tools they need. Ford has introduced Ultimaker 3D printers into factories across Europe, such as Spain, Italy, and Romania. The German design team provides designed electronic files, and through global connectivity and Ultimaker 3D printers, these tools can be used immediately.
．Paired with Software, Lowering the Barrier
Ford has gone a step further, using Trinkcle's modeling software Paramate, allowing employees without 3D design experience to create tool models; designs are sent directly to Cura slicing software, and printed on-site using the Ultimaker S5. Currently, most engineers are still responsible for designing complex aids. 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 initiatives have been very beneficial for Ford; compared to traditional manufacturing or outsourcing custom tools, they significantly save money and time. The Ford Focus uses over 50 custom-designed tools, aids, and fixtures, and further develops parts and accessories 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 these tools also offer significant ergonomic advantages for Ford's manufacturing team. After prolonged use, traditional metal tools can feel very heavy and affect employee health over time. The material properties of Ultimaker are often sufficient to replace metal tools (further reading: The Secret of 3D Printing to Lost-Wax Casting), making the work of assembly personnel easier, as every second on the production line counts.
．Looking Ahead
Ford is rapidly expanding the possibilities of 3D printing. While improving processes and producing aids, they hope that in the future, 3D printing will not only be used to make tools but also equipment and end-use parts. Not only in the automotive industry, but 3D printing technology has also made various advancements in aerospace and medical technology. (Further reading: Royal Netherlands Air Force: Taking Off with 3D Printing Technology!)
．Technology Sharing Session, Connecting Concept to Practice!
Want to learn more about 3D printing technology? 3DMart will hold a 3D Technology Sharing Session on Friday, December 21st! In addition to learning about different 3D printing technologies and applications, various samples, there will also be actual operation of 3D printers (tutorial worth over NT$3,000) and an introduction and application demonstration of 3D software Autodesk Inventor (this topic: achieving optimal design through Autodesk Inventor and extending it to manufacturing). Click here for details or register directly!
Follow our Facebook page to catch up on 3D technology: https://www.facebook.com/3dmart.com.tw/
Original link: https://ultimaker.com/en/stories/52786-ford-reinventing-efficient-manufacturing-using-3d-printing?fbclid=IwAR0p6k2FTvJ8LzeZreMFoLwQlqGvatSse5QdzM6uJ5uZlsIxPPt5h2g-yAo