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Additive Manufacturing at Ford Motor Company: Past, Present, and Future

Joy H. Forsmark, Ph.D., Research and Advanced Engineering, Ford Motor Company

June 2, 2016

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Outline

• Background

• Ford Experience in Additive Manufacturing

• Opportunities and Challenges for Automotive

• Closing Thoughts


History at Ford• 1988 – Purchased 3rd Stereolithography machine ever made

• Added firsts of several other AM technologies (SLS, FDM, LOM, etc)

• Developed an Additive Manufacturing Training and Development Center to train engineers in the AM technology

• 2000 – machines disbursed to various facilities around the company

• Today – 5 Global Rapid Manufacturing & Research Centers around the world utilizing AM technology to support internal work

• ~ 225,000 parts produced each year (primarily prototypes)


Additive Manufacturing Technologies

Source: ASTM International Committee F42 on AM: Roland Berger

Powder bed fusion (DMLS, DMLM, SLM)Thermal energy selectively fuses powder material

Powder bed fusion (SLS)Thermal energy selectively fuses powder material

Directed energy deposition (EBAM)Focused thermal energy is used to fuse/melt

material as it is deposited

Sheet laminationSheets of material are bonded to form an object

Binder jetting (sand printing)Liquid binder is selectively deposited onto powder

material

Material jetting (PolyJet)Droplets of material are jetted selectively; can be

multi-material

Material extrusion (FDM)Material is selectively dispensed through nozzle or

orifice by extruding molten material

Vat polymerization (SLA)Liquid photopolymer in a vat is selectively cured by UV

light

MetalsPolymers


Ford Experience: Stereolithography(SLA)

• Applications:

Master Patterns, Mock-up/Development, Line Trials, Show Parts, Clear Parts, Dump Box Tooling

• Method:

Selective Curing of UV Sensitive Epoxy Photopolymers


Ford Experience: Selective Laser Sintering (SLS)

• Applications:

Master Patterns, Direct Use, Intake Manifolds, Oil Pans, Grills, HVAC, Interior Parts, Wire Harness Trays, Kit Trays

• Method:

Nylon Powder fused together by a laser


Ford Experience: Fused Deposition Modeling (FDM)

• Applications:

Concept Models, Functional Prototypes, Jigs & Fixtures, RTV Molds, Thermoforming Patterns

• Method:

Melts and extrudes a plastic filament thru a small nozzle


Ford Experience: PolyJet Matrix –multi-material

• Applications:

Flexible ducts, door seals, gaskets, push buttons, electrical packaging, functional testing, registers, displays

• Method:

Prints photosensitive resin and immediately cure with UV


Ford Experience: Rapid Casting Technology (RCT) – Sand

• Applications:

• Prototype Sand Casting – Cyl. Heads, Trans Cases, RDU Housings/Components, Diff Carriers, Oil Pans, Exhaust Manifolds

• Method:

• Prints binding agent on powder material


General Applications in Automotive

• Visual Aids and Presentation Models

• Fit and Assembly Aids

• Customization for Manufacturing Ergonomics

• Patterns for castings

• Fixtures, gauges, design guides, & tooling

• Functional Prototypes (non-structural & structural)

• Final Functional Parts


Emerging Opportunities• Customized ergonomic aids for assembly plants

• Vehicle customization

• Faster prototype development and tooling

• Design opportunities through AM


Hand Clearance Issue Identified

3D Printed Hand Clearance Model

msmets 20150701

Emerging Opportunities: Plant Ergonomics Example


Challenges for Additive Manufacturing for Automotive

Translate Additive Manufacturing Technology to Support High Volume/Automotive-Grade Production


Business Case:


Faster cycle times for both

production and post-processing

Wider range of materials that meet automotive

grade standards and are cost-competitive to bulk

Development of appropriate cost thresholds for AM

versus conventional production methods


Quality:


• Reliable closed loop process control for

individual systems and across systems

• Integration of digital thread and software

• Automotive Specifications for materials and

processes: Leverage Aerospace Experience

• Development of engineering experience in

design for additive manufacturing


Understanding Process-Structure-Property Relationships to take AM to the next level in Automotive:


Functional structural prototypes and parts:

1) Mimic high volume production functionality

2) Production component meeting durability and structural functionality

requirements


Understanding Process-Structure-Property Relationships unique to AM processes:


Integrated Computational Materials Engineering (ICME):

Defining local and global variations in microstructure and properties with processing

to control performance

0

50

100

150

200

250

300

0 2 4 6 8 10

Stre

ss (M

Pa)

Strain (%)

Loc 2

Loc 4

Loc 5

Loc 9


Postprocessing:

Bigger concern as increase production volumes

• Hot Isostatic Pressing (HIPing) and Heat Treatment

• Resin Curing

• Residual Stresses due to Support Structure Removal

• Reclaiming and reuse of excess materials


Automotive Industry has experience in these areas but would drive to

minimize/eliminate/incorporate into other manufacturing processes


• Ford has used Additive Manufacturing technologies for many years to provide exciting automotive solutions

• These technologies hold promise for • Prototyping and tooling• Customization solutions (in-house and for customers)• Final volume production parts to take advantage of the unique design

possibilities of AM

• The automotive industry is poised to help set the direction of these technologies for years to come.

Final Thoughts


Questions?

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