Copyright: Ford of Europe GmbH
Ford – one of the largest car manufacturers in the world, is in the process of comprehensive modernization of its plant in Cologne, Germany, transforming it into a modern Electrification Center. The key element of the new factory is the 3D Printing Centre, where twelve technologically advanced 3D printers have been installed, producing plastic and metal parts. The largest of them allows the production of individual elements with dimensions of 2.4 x 1.2 x 1 meter. Ford’s goal is to release the first electric cars from the modernized factory by the end of this year.
“In Cologne, we mainly manufacture tools and fixtures for production lines,” says Nurah Al-Haj-Mustafa, Ford 3D printing engineer. “Each part can be absolutely unique. Nevertheless, every 3D print is the same in terms of quality and properties.” Produced in Cologne include: gauges for checking dimensions, templates for attaching the Ford logo, as well as massive structures of grippers for the arms of car body assembly robots. The new Ford 3D printing center can also print components for pilot and low-volume vehicles.
In addition to the flexibility of 3D printing, you can also save time and money with small quantities – up to 80% compared to the conventional injection molding process, where the production of the right mold is very complex. There is also the aspect of sustainability – 3D printing requires much less material, and in the case of metal powders, unused material can be reused. At the same time, the Production and Materials Team at the Ford Research and Innovation Center in Aachen is currently working on a pilot project to recycle 3D printing filaments.
The 3D printing process has been around for a long time at Ford in Cologne. As early as the 1990s, engineers at the Merkenich development center began 3D printing components for test vehicles and prototypes. Ford has set the standard in this field of additive manufacturing. For example, in 2019, the Ford Research and Innovation Center was able to produce the largest metal part ever produced using 3D printing. It was an aluminum intake manifold for a Ford F-150 engine converted by the late drifting legend Ken Block.
At Ford’s plant in Valencia, Spain, a 3D printing lab team has created a catalog of 5,000 printable parts that offer solutions for the different stages of the plant’s manufacturing process. In 2021 alone, the department successfully produced a total of 20,000 printed parts, and employees were able to order or suggest new parts as needed.
What is new and unique about the Cologne 3D printing center is the network connection to other areas and easy access. Any Ford employee can request a part through the app by adding their own technical drawing or describing what the part is needed for.
“We are aiming to start operations with short distances and little bureaucracy,” said Oliver Färber, who as manager of the engine factory is also responsible for the 3D printing center area. “The parts required by the workers are then specially designed by the team and can be produced very quickly.”
For example, a door edge protector has already been developed and is currently being tested in the final assembly line and could be used at other stations in the future. The ergonomically improved airbag installation aid is also tested. Parts are already 3D printed for the future production of the first “made in Cologne” e-model, with 1,800 impact protection devices currently being built for the new door transport system. They ensure that the door will not be damaged during transport to the line.
Source: www.ford.com
Photos: www.ford.com (press materials / all rights reserved)