As 3D printing technology continues to mature, its application in the automotive field has become commonplace.
August 26, 2024, according to the resource library, Ford Motor Company recently revealed that 3D printing technology was widely used in the design process of the new Electric Explorer. Specifically, Ford used Formlabs’ SLA and SLS 3D printers, including the Form 4, Form 3L, and SLS Fuse 1+ printer. At the same time, Ford designers also combined additive manufacturing technology with traditional subtractive manufacturing processes such as milling and injection molding to fully realize the advantages of 3D printing.
Formlabs’ Form 4 is the base model introduced last year, replacing the older Form 3+. Ahead of the official release, Ford partnered with Formlabs to serve as a beta tester for the Form 4. According to Ford, the latest generation of Formlabs printers allows designers to respond to requests within 24 hours, especially those from other factories and can be shipped the next day. Using stereolithography (SLA) technology, Ford is able to verify the design of interior and exterior vehicle components, such as mirror assemblies.
Selective Laser Sintering (SLS) technology is used to facilitate mechanical testing and played a key role in the design of Electric Explorer’s complex loading port. Ford said: “For the design of the cargo lid, the use of SLS was essential as we needed a functional part to test its mechanism. This design is very complex and cannot be achieved by other manufacturing methods. We cannot make it or produce it. with injection molding. » Produce samples. Therefore, using 3D printing to make this part from materials that can be physically tested is the best option.
Bruno Alves, additive manufacturing expert and mold expert at Ford, emphasized that even though the injection molding process is used in the design, 3D printing remains an effective complement. For example, the Electric Explorer’s door handle design requires the use of two rubber components for shock absorption and insulation, both manufactured using an injection molding process. Additionally, designers used 3D printing to create integrated molds for the internal injection molding machine.
Alves further explains, “This is a complex process because we use multiple inserts and each design may require multiple iterations. Generally, external injection molding can take two to three months. Thanks to in-house additive manufacturing, we were able to shorten this process. two to three weeks. For this project, if we relied on external tools, the time cost would increase significantly and we would struggle to deliver the parts on time.
When it comes to prototyping, speed is a key factor in adopting 3D printing technology, not just quantity or repeatability. As this report on the design of the Ford Electric Explorer shows, speed is key to accelerating electrification.
“Our competitors are growing faster and we must keep pace. The solution lies in testing new materials, new processes and new equipment. Today, if we cannot take advantage of additive manufacturing, we will not “We are not only unable to compete with our competitors. 3D printing allows us to provide customers with the highest quality products in a shorter time,” said Alves.
Ford has set an ambitious goal: to offer a range of fully electric vehicles by 2030. To achieve this goal, Ford must continue to explore cutting-edge technologies and try innovative new workflows. To stay ahead of the competition, they must think outside the box and integrate new materials, processes and equipment, such as in-house tools and 3D printing technology.
