Posted on 12/24/2013 10:30:27 AM PST by 2ndDivisionVet
One day, millions of car parts could be printed as quickly as newspapers and as easily as pushing a button on the office copy machine, saving months of development time and millions of dollars. 3D printing technology is making that day come sooner at Ford Motor Company. The development of the engine cover for the all-new Ford Mustang is the most recent example of the use of this technology. Ford uses 3D printing to quickly produce prototype parts, shaving months off the development time for individual components used in all of its vehicles, such as cylinder heads, intake manifolds and air vents. With traditional methods, an engineer would create a computer model of an intake manifold — the most complicated engine part — and wait about four months for one prototype at a cost of $500,000. With 3D printing, Ford can print the same part in four days, including multiple iterations and with no tooling limits — at a cost of $3,000.
“For the customer, this means better quality products that also can be weight-optimized to help improve fuel efficiency,” explains Paul Susalla, Ford section supervisor of rapid manufacturing. 3D printing saves millions of dollars in the product development process by eliminating the need for special tooling, or dedicated molds, for parts likely to change. The technology also allows engineers to experiment with more radical, innovative part designs inexpensively and quickly. Ford now is looking to what’s next in its 3D printing strategy, including opportunities to print production parts in metal, rather than just plastic, for prototypes. “This technology provides immense return for Ford and the entire manufacturing industry,” said Bill Russo, global director, Ford powertrain manufacturing and engineering.
How it works
3D printing works by printing one thin layer at a time from plastic, sand or other material, then gradually stacking the layers and building a finished piece to create a 3D object, similar to assembling a spool of CDs. “Today, 3D printing is not fast enough for the high-volume direct production manufacturing we do,” said Harold Sears, Ford additive manufacturing technical specialist. “But it is ideal for test parts, or niche production applications, that go through frequent development changes.”
Ford has been at the forefront of 3D printing for 25 years and was involved with the invention of 3D printing in the 1980s. In 1988, Ford purchased the third 3D printer ever made. Today, Ford uses selective laser sintering, fused deposition modeling and stereolithography 3D printing applications. Ford also works with suppliers to bring more technologies to market, including 3D sand printing.
Recent examples of Ford’s use of 3D sand printing include:
* Engine cover for all-new Ford Mustang
* Rotor supports, transmission cases, damper housings and end covers for new HF35 hybrid transmission for Ford C-MAX Hybrid, Fusion Hybrid
* Four-cylinder EcoBoost(r) engines for new Ford Fusion
* Brake rotors for Ford Explorer; the rotors were modified using 3D printing late in development to fix a brake noise discovered in durability testing, which could have delayed initial launch
* Exhaust manifolds for 3.5-liter EcoBoost in Ford F-150
“Many have referenced this technology as ushering in a third industrial revolution,” said Sears. “While that is yet to be determined, what we do know is manufacturing is continuing to go digital, the speed of these technologies is increasing and the variety of materials is expanding — all of which leads us to believe 3D printing presents a great opportunity for overall manufacturing.”
“ord has been at the forefront of 3D printing for 25 years and was involved with the invention of 3D printing in the 1980s. In 1988, Ford purchased the third 3D printer ever made”
Thanks.
hasnt al gore taken credit for this yet??
I ca’t get my head around printing things made of metal. Cnc machining, plasma or water cutting sure. Not printing.
Plastic engine covers for hot cars are of the devil. How boring.
Ford F-150, America’s best selling vehicle for almost 30 years...
US researchers share plans for low-cost metal 3D printer
http://www.freerepublic.com/focus/f-news/3100941/posts
3D Printing With Metal: Engineers Create DIY Welding 3D Printer For Under $1,500
http://www.freerepublic.com/focus/f-news/3097854/posts
China must hate where this is going
Good.
/johnny
Think...a nano elf welding teeny tiny parts together
Or not.
;>)
I hope Ford can print a section of lower intestine with an orfice large enough to accept their crap. My pride and joy in 2004 F350 4 door 6.0L truck has been a $42000 11 month truck. That is to say it has averaged 30 days a year in the shop at an average cost of $1800 per visit. Never again. Don’t know what the next one will be but it won’t be Ford. This one has been in the shop since August and might come home in time for New Years.
Give me manual windows & no anti lock brakes. I’m tired of paying big bucks to repair elec windows and this absolutely unnecessary, crappy brake system.
Sounds like you need to contact a lawyer about the Lemon Law on your vehicle. Or have you, already?
And soon you’ll get your gubmint-mandated backup camera.
Not gonna happen. Most people want those two things, for whatever reason. The only thing that has gone consistently wrong with my ancient Mercedes has been the electric windows. Haven’t been able to operate the rear ones for years now.
We are coming closer to the day when your kid doesn’t watch a commercial of some cheap toy and screams “Buy me that!”, instead he will say “Let’s download that open-source pattern and make it!”
I’ve driven 6 different F250 4x4s over 200,000 miles each.
Our family currently owns 9 F250s and F350s from an’87 up to a couple of 2013s. I live near where they make Dodge transmissions. Would own one if you gave it to me.
The only one with any major issues was one that an employee got stuck with and gunned the cold engine to about 8000rpm.
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