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Case Study
Ford Motor Company on the Road to 3D Manufacturing
To date, key challenges have stood in the way of 3D printing becoming a manufacturing tool for the automaker. The first issue is a fundamental one — conventional 3D printing technologies make parts layer-by-layer, slowly crafting one layer at a time, creating parts that aren’t nearly as robust as those stamped or injection molded. While the slow speed of this process is a major drawback, the bigger problem is that the parts produced are not isotropic and not durable enough to be used in production vehicles. In addition, most parts used in vehicles today must withstand temperature extremes from the hottest desert to the coldest Arctic environments and still maintain their integrity. With only a handful of stock materials available for 3D printers, meeting the automaker’s unique demands has not been possible.
Case Study
3D Printed Prototypes Streamline Equipment Introduction
Vauxhall set out to introduce a modified process hanger with a new part that would be used to support each vehicle body throughout the production process. This part is a critical piece and had to perfectly fit both the machinery and the auto body to create correct clearances and avoid damage during production.
Case Study
Bekaert's Journey to Manufacturing Digitalization with TCS
Bekaert, a major player in the steel wire industry, was facing significant challenges in its manufacturing operations due to outdated data platforms. The company was unable to trace genealogy beyond a week's data and lacked diagnostic analysis of plant operations, which severely hampered decision-making. The absence of automation in benchmarking operations and extensive reporting on plant management further complicated the situation. To enhance efficiency and effectiveness in multiple focus areas, Bekaert needed a modern data platform capable of managing large volumes of data and generating actionable insights. The company aimed to drive quality, overall equipment effectiveness (OEE), and plant productivity based on these insights.
Case Study
3D-Printing of Tooling Parts
Selective Laser Melting (SLM), an additive manufacturing technology, can be used for the production of tooling components with conformal cooling channels. ABB OY, Drives and Controls, was able to tremendously reduce the cycle time for a cabling grommet due to a redesign and optimization of a tooling insert. The optimized geometry of the part not only reduces the cycle time but also leads to less scrap parts in production.The aim of the case study of implementing conformal cooling for this insert was to improve the efficiency of the production and to increase the product quality resulting in less defective products.
Case Study
Delphi Leverages the M1 for Prototyping and Final Part Production
As the automotive industry continues to tighten product development timelines, compressing design time in the supplier network has been the go-to model to achieve desired results. Traditionally, to successfully address the economics of part production, Delphi has used technologies like injection molding to deliver parts at scale. The cost of tooling development and time associated has limited part production to be focused on mass-production only.
