Ford Motor Company’s launch of the all-electric Explorer marks a transformative moment in automotive manufacturing, powered by the company’s cutting-edge 3D printing technology. The new 3D printing center at their Cologne facility is at the heart of this shift, showing just how serious Ford is about boosting manufacturing efficiency and innovation. This move underscores how Ford is fully integrating additive manufacturing to reshape the future of automotive design.

Advanced 3D Printing at Ford’s Cologne Facility

In 2023, Ford revolutionized its manufacturing capabilities with the introduction of a state-of-the-art 3D printing center at its Cologne (Germany) facility. This facility is equipped with twelve high-tech 3D printers, including both plastic and metal printers, capable of producing parts of varying sizes—from small components to large, complex structures up to 2.4 meters in length. This advanced setup enables Ford to produce essential tools, fixtures, and components for both prototype and small-batch vehicle production, significantly enhancing the flexibility and precision of their manufacturing processes.

The 3D printing center at Cologne represents a major step forward in Ford’s push towards digitization and Industry 4.0. It not only accelerates the production of parts but also contributes to the overall efficiency and sustainability of the manufacturing process.

Speed and Flexibility in Manufacturing

One of the standout features of Ford’s new 3D printing center is its ability to fulfill design requests within a 24-hour timeframe. This rapid turnaround includes requests from other facilities, as long as they fall within overnight shipping range. This capability is crucial for keeping up with the fast-paced demands of modern automotive design and production.

Stereolithography (SLA) has been instrumental in validating both interior and exterior parts for the Electric Explorer. This technology allowed Ford to test and refine designs for complex components such as the sideview mirror assembly. For more intricate mechanical testing, such as the Electric Explorer’s charging port—a component with a highly complex design—selective laser sintering (SLS) proved essential. Bruno Alves, Ford’s additive manufacturing expert, highlighted the importance of SLS for this application: “For this charging cover, it was important to use SLS, based on the fact that we needed a functional part that would enable us to test the mechanisms. It’s a really complex design that we are not able to produce in any other way.”

Enhancing Traditional Manufacturing with 3D Printing

Ford’s integration of 3D printing extends beyond just creating new parts; it complements traditional manufacturing methods such as injection molding. For instance, the door handle design of the Electric Explorer includes rubber components for damping and insulation. While these components were injection molded, Ford used 3D printing to create inset molds for their in-house injection molding machines. This approach allowed Ford to expedite the production process significantly. As Alves points out, “Normally, external injection molding will take maybe two or three months. Internally, using additive manufacturing, we can speed up the process to maybe two weeks, three weeks maximum.”

Driving Innovation and Efficiency

The Cologne 3D printing center is not only a testament to Ford’s commitment to innovation but also a critical component of their strategy to achieve an entirely electric lineup by 2030. The center’s ability to rapidly prototype and produce components supports Ford’s broader goals of digitization and efficiency in manufacturing.

Ford’s focus on integrating new materials, processes, and machinery into their production workflows underscores their dedication to staying competitive in a rapidly evolving industry. Alves adds, “Our competitors are speeding up the developing process. We need to speed up as well. So the solution is to test new materials, new processes, and new machines coming to market. Currently, 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. 3D printing allows us to, in a shorter time, have the best product that we can offer for the clients.”

Driving the Future Forward

Ford’s Electric Explorer is a prime example of how advanced 3D printing technology is revolutionizing automotive manufacturing. The Cologne 3D printing center has not only enhanced Ford’s production capabilities but also reinforced the company’s commitment to innovation and efficiency. As Ford continues to explore new technologies and methodologies, the Electric Explorer stands as a testament to the company’s dedication to shaping the future of the automotive industry. With these advancements, Ford is well-positioned to lead the charge toward a new era of electrification and manufacturing excellence.

Tulfa Additive Manufacturing (Tulfa AM) is dedicated to using 3D printing to develop innovative products that meet the industry’s evolving needs. With Tulfa’s advanced capabilities, we aim to create solutions that are efficient, sustainable, and tailored to our clients’ requirements, driving meaningful progress in manufacturing practices.

For more information, write to us at: hello@tulfa.com