3D printing is being used in an increasing number of industries in new ways. The accessible technology enables short iterations, makes production processes more efficient and encourages innovation. Most recently, research firm IDC predicted that 3D printing in the manufacturing industry will take off in the coming year, rising 21.8% from last year. Ford deploys 3D printing in manufacturing and tooling optimisation even before a car goes into production, among other areas.
Ford uses many custom-made tools during the production of their vehicles. These tools are often designed for one specific task and model. Having these tools manufactured externally is time-consuming and very expensive.
Ford's team in Cologne is pioneering the development of every new vehicle design before it goes into mass production. Many manufacturing companies are implementing 3D printing to optimise their current production process. Ford is taking this a step further: by having a dedicated 3D workshop with Ultimaker printers in the pilot plant, Ford can produce and optimise all tools even before a car goes into mass production. This gives Ford engineers the opportunity to extensively test the custom 3D printed tools.
The company saves a lot of time and money by no longer having tools made externally. 3D printing saves on average around 1,000 euros per tool. The 3D printed tools also have ergonomic benefits for staff. They are just as strong as traditional metal versions, but a lot lighter. In this way, employees are less stressed.
Ford is now expanding its 3D printing capabilities. For example, it is experimenting with printing spare parts. Besides Cologne, Ford plans to deploy the printers in other workshops in Europe.
Content and image: Paul Heiden, SVP Product Management at Ultimaker
