Ford Motor Company has utilized SLA and SLS 3D printers by Formlabs to develop prototypes for various parts of its new Electric Explorer SUV.
Ford, ranked as the world’s sixth-largest car maker, employed Formlabs’ latest 3D printer, the Form 4, to enhance its vehicle design process, alongside the existing Formlabs Form 3L and Fuse 1+ 30W printers.
The organization leveraged 3D printing technology for developing prototypes for essential elements of its electric SUV, such as mirrors, handles, charging ports, and parts of the dashboard. This approach has enabled the design team to explore more innovative solutions, develop intricate designs effortlessly, and fabricate prototype modifications rapidly, within hours instead of days.
Through the adoption of additive manufacturing techniques, Ford aims to fulfill its promise of converting its European product line to fully electric by the year 2030. The expediency offered by 3D printing plays a crucial role in achieving this ambitious goal within the specified timeframe.
“If we didn’t have access to additive manufacturing, we would not be able to compete with the competitors, we would not be able to be so fast,” Bruno Alves, an expert in Additive Manufacturing and Tooling Specialist at Ford, remarked.
“Additive manufacturing is very important in the development process. It gives you the opportunity to produce parts very quickly, very efficiently, and reduce costs,” Sandro Piroddi, Supervisor of the Rapid Technology Center at Ford, also noted.
Ford leverages Formlabs’ new Form 4
Ford’s PD Merkenich Rapid Technology Center stands as a pivotal development hub that focuses on shaping all passenger vehicles designated for the European market. At this facility, technologies such as SLS, SLA, FDM, and metal 3D printing are integral in crafting vehicle prototypes.
Resin 3D printers from Formlabs are notably essential in the design process of Ford’s latest electric vehicles, including the Electric Explorer SUV. SLA 3D printers at the workshop are preferred for prototypes needing high-quality surface finishes, allowing for rapid production and frequent iterations.
Ford was an early adopter of the Form 4, Formlabs’ newest MSLA 3D printer.
Introduced earlier this year, the Form 4 enhances the production with its high-speed 3D printing capabilities, reliability, and superior material properties. Compared to its predecessor, the Form 3+, it delivers significant advancements, completing standard print jobs in less than two hours and achieving vertical speeds of up to 100 mm/hr.
“The Form 4 is very fast, I think it is the best machine that I’ve seen until now in terms of speed. It’s really a very good upgrade compared to the previous models,” commented Alves. “It’s easier to operate, so it’s much easier for the operators in our workshop to learn how to work with the machine and get parts with good quality.”
Piroddi called the Form 4 a “game changer” thanks to its fast 3D printing speeds, allowing Ford’s development team to increase throughput and achieve more design flexibility. The team can now fulfil more requests in under 24 hours and deliver overnight shipments of parts to the UK.
SLA 3D printing has played a key role in validating the design of many exterior and interior parts for the new Ford Electric Explorer. Formlabs’ Form 3L, a large-format SLA 3D printer, was used to 3D print big exterior parts in one piece. This included the rear-view mirror cap, the charging port cover, and dashboard features.
Advancements in Electric Vehicle Development with SLS 3D Printing
Ford has integrated an extensive array of SLS 3D printers to evaluate mechanical car components. Among these printers is the Formlabs’ Fuse 1+ 30W, capable of 3D printing PA-12 nylon material that mimics characteristics akin to those found in injection-molded production parts.
The organization also took the lead in testing Formlabs’ Fuse Blast, an automated system designed to clean and polish 3D printed parts. This innovation has significantly sped up Ford’s prototyping operations by eliminating manual post-processing stages.
One of the significant benefits of SLS technology is that it can create intricate designs without needing support structures. Utilizing the capabilities of the Fuse 1+ 30W, Ford produced various intricate mechanical components for its new model, the Explorer. This includes the electric SUV’s complex charging port, a component that was claimed to be unachievable through other manufacturing techniques.
“It’s a really complex design that we are not able to produce in any other way. We cannot mill this part. We cannot use injection molding to produce just some samples,” stated Alves. “So the best way is to print in a material that we can test physically.”
3D printing unlocks in-house injection molding
Ford has also combined traditional manufacturing processes with 3D printed rapid tooling. This allows the team to determine and select the most suitable production process and material for different applications, cutting costs and increasing workflow efficiency.
In crash tests for vehicles, it’s imperative that components are crafted using identical materials and processes as those in the final mass-produced parts. Frequently, plastic parts are created via injection molding, a method that traditionally requires expensive and slow metal tooling.
“We see great potential in utilizing 3D printing for injection molding inserts due to the rapidity with which designs can be iterated. We print the cavity and core inserts, allowing for swift modifications within the tooling to inject the parts,” added Alves.
For the latest model of the Explorer, Ford internally developed rubber components for the SUV’s door handle assembly utilizing 3D printed mold inserts. Normally, external injection molding can span two to three months. However, using in-house additive manufacturing for the mold inserts, Ford manages to cut this timeframe to less than three weeks. The inserts are produced using Rigid 10K resin on StereoLithography (SLA) 3D printers and Nylon 12 Powder on Selective Laser Sintering (SLS) platforms.
“Had we opted for external manufacturing tools for this project, it would have significantly prolonged the process, preventing timely delivery of the parts,” explained Alves.
Injection molding inserts 3D printed in Formlabs Rigid 10K Resin. Photo via Formlabs.
Additive manufacturing for automotive applications
Ford isn’t the only automotive manufacturer integrating additive manufacturing into its design and production workflow.
Last year, Global industrial 3D printer manufacturer INTAMSYS partnered with printing materials supplier KEXCELLED to provide FDM 3D printing capabilities to the Automotive Division of SIKA in China.
By 3D printing car parts, SIKA has experienced significant time and cost reductions of up to 90% during the prototyping and development phases for the automotive sector. Using INTAMSYS’ advanced 3D printing technology, they have been able to produce various car components, such as custom bumpers, different steering wheel models, parts for racing vehicles, and bespoke designs for tail logo fixtures.
Meanwhile, the multinational corporation from Japan, Toyota, has incorporated the Zortrax M300 Plus for 3D printing assembly jigs and fixtures. Their use of this FDM 3D printer has been crucial in enhancing their vehicle assembly processes, thereby minimizing both operational costs and production lead times for essential manufacturing tools and spare parts.