Boosting 3D Printing Design with Simulation: Ford's Experience with Altair Inspire
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
Applicable Industries
- Automotive
- Equipment & Machinery
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Additive Manufacturing
- Manufacturing Process Simulation
Services
- Testing & Certification
About The Customer
Ford Motor Company is a Fortune 50 automotive company that operates plants worldwide, producing millions of vehicles annually. Committed to being the world's most reliable mobility and intelligent vehicle design company, Ford maintains engineering centers in various locations, including the USA, India, Mexico, Germany, and Brazil. The company has been working with Altair for over 30 years to support its product development activities. Today, Ford employs Altair software globally to aid in the development of its cars, trucks, and heavy equipment.
The Challenge
Ford Motor Company, a global automotive giant, was facing challenges in the realm of Additive Manufacturing (AM), a process that involves adding material layer by layer to manufacture components. This technology, while promising significant benefits such as cost reduction, tooling improvements, and the ability to create complex designs, is relatively new. As a result, the industry's expertise in AM is not on par with traditional manufacturing. Ford found it challenging to set printer parameters correctly, as incorrect settings could lead to structural failures, performance deficiencies, and aesthetic issues in the printed components. The pursuit of mechanical design efficiency often led to overlooking critical considerations.
The Solution
Ford implemented AM along with Altair Inspire's 3D printing simulation within their product development process. This combination helped Ford identify potential error states throughout the manufacturing lifecycle, providing crucial information to optimize and ensure first-time quality through design. The focus was on bracket design, which aimed to improve heat management via internal cooling channel design. The simulation allowed the creation of complex, optimal geometries for brackets, promoting more effective heat dissipation and better mechanical behavior and dimension control. Altair Inspire's 3D printing simulation, coupled with a design of experiment process created with Altair HyperStudy, helped solve issues typically encountered at the printing stage, such as detachment of supports and aesthetic finish problems. It also enabled printer parameter optimization for peak performance.
Operational Impact
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