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 whats 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 Fords 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.
Ping
Someday kids will be able to buy that at ToysRUs.
Next Big Thing : Will 3D printing really become a household trend?
http://www.youtube.com/watch?v=y4nENtfXQNk
They really wrecked the visuals with some of these sleek side window designs. They forgot what windows were for??
eventually I think it will
Once upon a time they foresaw no use for computers beyond a few applications for a few organizations.
I Worked on some small parts that were "Design Studies" for Ford in the mid 90's from 3D Models we made. Yes it was cheaper and yes overall programs ran in those big numbers they mentioned. My guess is today those overall program dollars are much, much less..
Need a last minute Christmas gift? How about a $12,000 3D printed gun?
I guess it works.
ahh you got the 6’0 power stroke. hope ya got a good paying job.
What’s neat about this tech is that you don’t need an expensive CAD program to use them. Any 3D software will do (Lightwave 3D, Modo, Maya, Max, etc.) as long as there are printer drivers for the software. The rules are that the model has to be sized to a scale the printer can actually handle, and there can’t be any open or overlapping polygons in the model. In other words, the mesh has to be perfectly “clean.”
I think they are confusing rapid prototyping of parts during development.
It is a long road to millions of them coming out the same way they come out of an office copier.
I’m an electrician in the Alberta oil field. It seems most trucks I see are Gmc and Dodge.
Naah. I just suck it up and move out. It is a hundred miles to any where from where we live. I get the truck back this time it is going to sale. Don’t want Dodge or GM for replacement. Perhaps I can find a 1970 International ton and a half truck. Put a pick up box on it and call it good.
Best thing since sliced bread if you own a boat or pull a trailer now and again.
Especially for the hooking up process.
Installed one on my old Dodge Ram, my new F150 came with one, saved me the trouble.
The back proximity sensors ain't bad either.
Should they be government mandated, hell no!
But danged nice to have if you have a use.
Open windows cause drag and impact the MPG.
Agree and no ECM’s just (KISS)keep it simple stupid in CA auto repairs start at $120.00 an hour at a dealer.
Saves a lot of marital distress when hooking up trailers! I bought one from Harbor Freight the second they were in stock 10 years ago.
“Best thing since sliced bread if you own a boat or pull a trailer now and again”=
Blazer or wagon with the rear lowering window and /or drop the tailgate.
Man, oh man, oh man!
Have you ever hit the nail on the head, LOL.
My wife has to be the worst *ground guide* in the world.
Could never figure what the hell she was trying to signal while I was backing up.
Always had to get out of the truck and see the position myself.
When an inch counts, she had me at least a foot off :)
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