Ford webinar: how ford uses bigrep 3d printers on the factory floor
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Ford Webinar: How Ford Makes use of BigRep 3D Printers on The Manufacturing facility Ground

As we commonly define, the automotive business is quickly adopting 3D printing, particularly massive format 3D printers. One of many corporations that auto producers are going to is BigRep. And BigRep welcomes these clients by implementing their suggestions into their machines and by creating content material catered to their particular wants, such because the webinar: How Ford is Optimizing Manufacturing with 3D Printed Tooling and Fixtures. It’s crammed with helpful data and the day-to-day operations of meeting staff and the way 3D printed instruments make their job simpler and safer. 

Lars Bognar, a Analysis Engineer at Ford, explains a number of of the important thing advantages to utilizing AM in auto crops. Buying managers are typically delighted by AM as a result of it reduces their dependence on suppliers, who usually change costs and run out of stock. These engaged on the plant ground admire that 3D printed instruments are extra ergonomic than conventional instruments, making them simpler and extra snug to deal with. And quicker iterations for prototyping means shorter growth instances. Whereas customization is a giant profit, it additionally means there isn’t a certification or standardization, so options usually must be created from scratch.

Lars goes over a number of case research, beginning with a software for positioning steel elements to be manually welded. It is a low-run setup for prototypes, so typically the tooling is thrown away after the manufacturing run of a pair hundred items is full. By 3D printing a number of the tooling, they’ve possibility of recycling the elements by shredding them into plastic pellets that may be reused. 

For each high-volume and low-volume purposes, 3D printed hand jigs can be utilized as templates to align holes and elements. A component that’s used as soon as each minute must be as mild as potential, and by decreasing the burden of a jig by 1 kg, a employee will elevate 600 kg much less throughout a single shift. The vary of supplies that can be utilized on BigRep machines permits engineers to decide on the fabric that’s as sturdy or as mild as is required for the precise job.

3D printed massive scale sensor fixture (890 x 1010 x 110 mm). Printed with a BigRep and Black ProHT Filament. Print time: 51 hours. Half weight: four.1 Kg.

Many BigRep customers report that the preliminary software they acquired the printer for isn’t even what they use it most for. Whenever you get a 3D printer, it’s inconceivable to foretell every little thing it will likely be used for. Lars factors to state of affairs within the plant the place administration needed an answer for masking massive cement blocks on the manufacturing unit ground however they didn’t need to pay for injection molded elements. With the BigRep, it was straightforward and reasonably priced to print customized covers out of versatile TPU. And seeing the answer materialize so rapidly helped the plant staff take pleasure in a brand new mindset to on-the-spot downside fixing. Lars says they initially bought a BigRep and not using a particular software however rapidly bought extra when the primary one was working 24/7 for weeks at a time.

One other AM software Lars factors to is mockups, which permit staff and designers to check plant gear like grippers and carriers on elements that they don’t even have but. For these assessments, solely the geometry of the half is required; it doesn’t must be purposeful in any respect. Mockups are wanted when an element continues to be being developed concurrently to the organising of the manufacturing plant in addition to for parts that interface with a lot of completely different elements and wish many iterations. It’s less expensive to offer mockups to the engineers in all of the completely different departments which can be creating elements that may work together with the element than to present all of them a purposeful element. Different instances mockups are used when it’s very tough to ship a element, like a prototype battery.

Frank Marangell, Chief Enterprise Officer of BigRep, then offers some particulars on their machines. He explains that their innovation middle NOWLAB is continually researching new AM purposes, resembling their airless tire.

The 4 foremost auto purposes for which BigRep clients use their machines embody prototyping, tooling, patterns/molds/casting, and end-use elements. A pleasant graphic of the accessible supplies is supplied that shows the associated fee and efficiency of various thermoplastics, from the usual ABS to high-performance PEKK.

The unique BigRep One is greater than the newer Studio however not enclosed so it might probably’t deal with as many supplies. For customers that want dimension and efficiency, they developed the Professional that options new MXT (Metering Extruder Know-how) toolheads for extra supplies and printing that’s extra correct, repeatable, and 5 to 10 instances quicker. A Bosch CNC controller measures over 500 knowledge factors per second and routinely adjusts movement to stay inside tolerances which can be decided by earlier prints. The upcoming Edge is designed for the automotive and aerospace industries because it options an extra-long construct quantity that may be heated to 200°C, and it’ll print 10 to 20 instances quicker than competing printers.

For these within the auto business who need to take part on the AM enjoyable, Lars advises that one of the simplest ways to persuade administration to purchase a large-format printer is to purchase a small printer and present all of them the options you give you.

You’ll be able to watch / pay attention the total webinar right here.

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