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 dedicated to accelerating automotive manufacturing 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 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 undergo years of development before mass production. Research and advanced engineering teams continuously improve workflows, creating various jigs, tools, and specialized fixtures.
．Selecting 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 customized tools is time-consuming and expensive. To obtain tools quickly, 3D printing has become Ford Motor Company's new production assistant.
Not only did they establish a dedicated 3D printing team, but they also adopted SLS (Selective Laser Sintering 3D printing technology) for production. Since SLS technology requires post-processing to remove powder, Ford also started using FFF technology Ultimaker 3D printers, which allow for more direct access to 3D printed products compared to SLS printing technology.
Due to their ease of operation, everyone from engineers to operators can use 3D printers to create the tools they need. Ford stated: "We chose Ultimaker because of its excellent cost-effectiveness, and we value its industrial-grade high quality and stability."
．To do good work, one must first sharpen one's tools.
Many manufacturing factories use 3D printing to improve their manufacturing processes. However, by establishing a dedicated 3D printing workshop, Ford can verify all design elements before new car models enter mass production, helping engineers gain more time to modify or replace tool designs. These specialized tools not only shorten production time but also focus on employee ergonomics, and these details will improve the efficiency of the production line.
Ford Motor Company stated: "At the same time, the openness of the filaments allows us to use industrial materials, which helps create 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 to factories across Europe, such as in 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 to entry
Ford has gone a step further, using Trinckle's modeling software Paramate, to enable employees without 3D design experience to create tool models; designs are sent directly to Cura slicing software and 3D printed on-site with the Ultimaker S5. Currently, most engineers are still needed to design complex fixtures. 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 ventures have been very beneficial for Ford; compared to traditional manufacturing or outsourcing custom tools, they can significantly save money and time. Ford Focus uses more than 50 custom-designed tools, fixtures, and jigs, and further develops production line components; 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. Ultimaker's material properties are often sufficient to replace metal tools (further reading: The Secret to 3D Printing to Lost-Wax Casting), making the work of assembly personnel easier, as every minute and second on the production line counts.
．Looking Ahead
Ford is rapidly expanding the possibilities of 3D printing. While improving processes and creating fixtures, they hope that in the future, 3D printing will not only create tools but also manufacture equipment and end-use parts. Not only in the automotive industry, 3D printing technology has also made various advancements in aerospace and medical technology. (Further reading: Royal Netherlands Air Force: 3D Printing Technology Takes Flight!)
．Technology Sharing Session: Connecting Concepts 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, and various samples, there will also be a practical demonstration of 3D printers (the tutorial is valued at over NT$3000) and an introduction and application demonstration of 3D software Autodesk Inventor (this topic: achieving optimized design and extending to manufacturing through Autodesk Inventor). Click here for details or register directly!
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Original link: https://ultimaker.com/en/stories/52786-ford-reinventing-efficient-manufacturing-using-3d-printing?fbclid=IwAR0p6k2FTvJ8LzeZreMFoLwQlqGvatSse5QdzM6uJ5uZlsIxPPt5h2g-yAo