US car company Ford Motor Company is experimenting with 3D printing large car parts. For this, the company is using a Stratasys Infinite Build 3D printer.
The use of 3D printers in the automotive industry is not new. Until now, however, the printers have mainly been used to quickly produce prototype parts. Ford Motor Company is now investigating whether it is possible to 3D-print large parts consisting of a single component using the Stratasys Infinite Build 3D printer.
Producing short-run parts
Specifically, Ford wants to use the 3D printer to create prototypes, tools and car parts that are produced in short runs, such as Ford Performance parts and personalised car parts. The new 3D printer is located at the Ford Research and Innovation Centre in Dearborn in the US state of Michigan.
Ford argues that 3D printing can bring substantial gains in the production of cars and car parts. For example, it is possible to use 3D printers to make lighter parts, which help improve the fuel efficiency of vehicles. As an example, the carmaker cites a 3D-printed spoiler, which can weigh half as much as a metal spoiler.
More cost-efficient
In addition, Ford points out that parts for prototypes and specialised race cars, for example, that are produced in small batches can be made more cost-efficiently with a 3D printer than with traditional manufacturing methods. Finally, prototypes can be produced significantly faster as they can be printed directly. Ford expects prototypes to be available within days as a result, whereas this process now often takes months.
The Stratasys Infinite Build 3D printer is a 3D printer that uses fused deposition modelling (FDM), a rapid prototyping technique where material is melted together layer by layer to build an object. What makes the Stratasys Infinite Build 3D printer special is the fact that it prints vertically, where most other 3D printers print horizontally. When printing horizontally, the printer is bound to a maximum height, whereas when printing vertically, it is theoretically possible to produce objects of an unlimited size.
Robotic arm
The 3D printer converts raw material into a printed component. If this raw material runs out, it is automatically replenished by an industrial robotic arm. This combination allows the 3D printer to operate unattended for hours or even days.
By: Wouter Hoeffnagel
Photos: Ford
