[3D Printing News] Volkswagen Autoeuropa: Achieving Maximum Production Efficiency with 3D Printed Tools and Jigs
Volkswagen Autoeuropa, responsible for manufacturing iconic VW models like the Scirocco and Sharan, with an annual production of 100,000 vehicles, is now leveraging 3D printing technology to revolutionize its workflow.
3D printing manufacturing facilities are used daily on the production line, eliminating the need to rely on external suppliers for tools, jigs, and equipment. This has significantly reduced costs and shortened lead times from weeks to just a few days.
3D Printing and Manufacturing Support
Autoeuropa Volkswagen's case demonstrates the immense value that 3D printing brings to the automotive industry. While 3D printing has traditionally been associated with creating models, manufacturing companies still have the potential to create custom tools, equipment,
jigs, and other manufacturing aids.
Volkswagen Autoeuropa, responsible for manufacturing iconic VW models like the Scirocco and Sharan, with an annual production of 100,000 vehicles, is now leveraging 3D printing technology to revolutionize its workflow.
3D printing manufacturing facilities are used daily on the production line, eliminating the need to rely on external suppliers for tools, jigs, and equipment. This has significantly reduced costs and shortened lead times from weeks to just a few days.
3D Printing and Manufacturing Support
Autoeuropa Volkswagen's case demonstrates the immense value that 3D printing brings to the automotive industry. While 3D printing has traditionally been associated with creating models, manufacturing companies still have the potential to create custom tools, equipment,
jigs, and other manufacturing aids.
Through 3D printing, highly complex designs can be created, and rapid adjustments and modifications can be made without incurring additional costs or extending lead times.
These tools can be adjusted on demand, making function and form the primary drivers of design, rather than cost or time.
This 3D-printed tire protection jig used to cost 800 Euros, but now only costs 21 Euros to print. Tool development time has been reduced from 56 days to 10 days.
External Suppliers
Before collaborating with Ultimaker, Autoeuropa Volkswagen relied on external suppliers for tools, equipment, and fixtures.
These third-party companies would often take several weeks to process models and manufacture the corresponding tools, significantly hindering production and negatively impacting the workflow.
Outsourcing also proved to be expensive, especially if design modifications were needed. When developing new manufacturing aids, Autoeuropa Volkswagen often had to employ a trial-and-error approach.
This was not practical when collaborating with other companies.
Saving Time and Money with 3D Printing
After validating the concept in 2014, Autoeuropa Volkswagen now owns 7 Ultimakers, with 93% of previously externally manufactured tools now produced in-house.
3D printing can save 91% of mold development costs and shorten development time by 95%.
As explained by Luis Pascoa, Plant Foreman Manager at Volkswagen:
"By printing just a few tools, we can recoup our initial investment."
This 3D-printed tire protection jig used to cost 800 Euros, but now only costs 21 Euros to print. Tool development time has been reduced from 56 days to 10 days.
External Suppliers
Before collaborating with Ultimaker, Autoeuropa Volkswagen relied on external suppliers for tools, equipment, and fixtures.
These third-party companies would often take several weeks to process models and manufacture the corresponding tools, significantly hindering production and negatively impacting the workflow.
Outsourcing also proved to be expensive, especially if design modifications were needed. When developing new manufacturing aids, Autoeuropa Volkswagen often had to employ a trial-and-error approach.
This was not practical when collaborating with other companies.
Saving Time and Money with 3D Printing
After validating the concept in 2014, Autoeuropa Volkswagen now owns 7 Ultimakers, with 93% of previously externally manufactured tools now produced in-house.
3D printing can save 91% of mold development costs and shorten development time by 95%.
As explained by Luis Pascoa, Plant Foreman Manager at Volkswagen:
"By printing just a few tools, we can recoup our initial investment."
This flip-up badge took 35 days to source externally during development, costing a total of 400 Euros. With 3D printing, the project was completed in 4 days, reducing the cost to 10 Euros. This window ruler cost 180 Euros per piece, but now with 3D printing, it only costs 35 Euros. Development time was reduced from 8 days to 6 days.
After 2016, the facility saved 150,000 Euros, a figure projected to increase to a reduction of 250,000 Euros in 2017. The initial investment in Ultimaker machines was fully recouped within 2 months.
In addition to these time and cost savings, 3D printed tools are more ergonomic and can provide greater feedback to operators, as iterative designs can be incorporated more easily,
all achieving unprecedented efficiency. The 3D printed tools produced by Volkswagen are considered best practice within the Volkswagen Group.
Changing the Workflow
By producing tools in-house, Autoeuropa Volkswagen can bypass the procurement department and collaborate directly with developers to develop new ideas or improve tools. Previously, this was not possible, as only a few
ideas could be implemented in a timely manner. A new tool can be printed overnight and tested by developers on the production line the next morning. Their feedback can be incorporated into continuous iterative designs
until the perfect tool is completed. This tool can be printed many times to meet demand and at a low cost.
Manufacturing aids can now be 3D printed overnight and tested the next morning, significantly accelerating the development process.
3D Printing and Manufacturing
3D printing offers the potential for revolutionary manufacturing. Using in-house 3D printers, prototypes, tools, and end-use parts can be quickly produced at a fraction of the outsourcing cost. Through desktop 3D printing,
manufacturing companies can streamline production processes and achieve higher efficiency than ever before.
As Luis Pascoa states:
"Ultimaker is a low-cost solution that delivers high standards and high-quality results. If you consider its application across the entire automotive industry, the potential is enormous!"
Autoeuropa Volkswagen clearly demonstrates how 3D printing can revolutionize a car company's workflow. If you are interested in learning what Ultimaker can do for your business, please contact us for a quote.
After 2016, the facility saved 150,000 Euros, a figure projected to increase to a reduction of 250,000 Euros in 2017. The initial investment in Ultimaker machines was fully recouped within 2 months.
In addition to these time and cost savings, 3D printed tools are more ergonomic and can provide greater feedback to operators, as iterative designs can be incorporated more easily,
all achieving unprecedented efficiency. The 3D printed tools produced by Volkswagen are considered best practice within the Volkswagen Group.
Changing the Workflow
By producing tools in-house, Autoeuropa Volkswagen can bypass the procurement department and collaborate directly with developers to develop new ideas or improve tools. Previously, this was not possible, as only a few
ideas could be implemented in a timely manner. A new tool can be printed overnight and tested by developers on the production line the next morning. Their feedback can be incorporated into continuous iterative designs
until the perfect tool is completed. This tool can be printed many times to meet demand and at a low cost.
Manufacturing aids can now be 3D printed overnight and tested the next morning, significantly accelerating the development process.
3D Printing and Manufacturing
3D printing offers the potential for revolutionary manufacturing. Using in-house 3D printers, prototypes, tools, and end-use parts can be quickly produced at a fraction of the outsourcing cost. Through desktop 3D printing,
manufacturing companies can streamline production processes and achieve higher efficiency than ever before.
As Luis Pascoa states:
"Ultimaker is a low-cost solution that delivers high standards and high-quality results. If you consider its application across the entire automotive industry, the potential is enormous!"
Autoeuropa Volkswagen clearly demonstrates how 3D printing can revolutionize a car company's workflow. If you are interested in learning what Ultimaker can do for your business, please contact us for a quote.