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Ford plans 3D printed parts

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Ford Motor Company is exploring how large one-piece auto parts, like car spoilers, could be printed for prototyping and future production vehicles, as the first automaker to pilot the Stratasys Infinite Build 3D printer.

Capable of printing car parts of practically any shape or length, the Stratasys Infinite Build system could be a breakthrough for vehicle manufacturing, providing a more efficient and affordable way to produce tooling, prototype parts, or components at low volumes, like Ford Performance vehicles, or for personalized car parts.

“With the Infinite Build technology, we are now able to print large tools, fixtures, and components, making us more nimble in design iterations,” said Ellen Lee, Ford technical leader for additive manufacturing research. “We’re excited to have early access to Stratasys’ new technology in order to help steer the development of large scale printing for automotive applications and requirements.”

The new 3D print system is located at Ford’s Research and Innovation Center in Dearborn.

An emerging technology for manufacturing

As 3D printing becomes increasingly efficient and affordable, companies are employing this emerging technology for manufacturing applications in everything from aerospace, to education, to medicine. Wider adoption in 3D printing has been driven by recent technology advances, new areas of application and government support, according to Global Industry Analysts Inc. By 2020, the global market for 3D printing is expected to reach $9.6 billion, the organization reported.

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In the future, 3D printing could have immense benefits for automotive production, including the ability to produce lighter-weight parts, which may help improve fuel efficiency. A 3D-printed spoiler, for instance, may weigh less than half of its metal-cast equivalent.

Additionally, 3D printing is a more cost-efficient way to produce parts only needed at low volumes, like prototypes and specialized parts for racecars. Further, Ford also may use the technology to make larger printed tooling and fixtures as well as personalized components for customers.

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How it works

Specifications for the part are transferred from the computer-aided design program to the printer’s computer, which analyzes the design. Then, the device goes to work, printing one layer of material at a time – in this case, plastic – and then gradually stacking the layers into a finished 3D object.

When the system detects that the raw material or supply material canister is empty, a robotic arm automatically replaces it with a full canister. This allows the printer to operate for hours or days while unattended.

Benefits of 3D printing

Though 3D printing isn’t yet fast enough for high-volume production manufacturing, it is a more cost-efficient way to produce parts only needed at low volumes, like prototypes and specialized parts for racecars. In addition, when not limited by the constraints of mass production processes, components can be designed to function more efficiently.

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Using traditional methods, an engineer would create a computer model of the part and wait for months for prototype tooling to be produced. With 3D printing, Ford can print the same part in days at a significantly reduced cost. For example, a prototype for a new intake manifold could be produced over a couple of days as opposed to several months, at an order of magnitude lower cost.

Cars

Why sports cars make us feel good

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Forget romance, fine dining or an epic boxset binge – new preliminary research reveals that driving a sports car on a daily basis is among the best ways to boost your sense of wellbeing and emotional fulfilment.

The study measured “buzz moments” – peak thrills that play a vital role in our overall wellness – as volunteers cheered on their favourite football team, watched a gripping Game of Thrones episode, enjoyed a passionate kiss with a loved one or took an intense salsa dancing class. Only the occasional highs of riding a roller coaster ranked higher than the daily buzz of a commute in a sports car.

Working with neuroscientists and designers, Ford brought the research to life with the unique Ford Performance Buzz Car: a customised Ford Focus RS incorporating wearable and artificial intelligence technology to animate the driver’s emotions in real time across the car’s exterior. 

Watch the video here https://youtu.be/AFpt6jziFsU

“A roller coaster may be good for a quick thrill, but it’s not great for getting you to work every day,” said Dr Harry Witchel, Discipline Leader in Physiology. “This study shows how driving a performance car does much more than get you from A to B – it could be a valuable part of your daily wellbeing routine.”

Study participants who sat behind the wheel of a Ford Focus RS, Focus ST or Mustang experienced an average of 2.1 high-intensity buzz moments during a typical commute; this compared with an average of 3 buzz moments while riding on a roller coaster, 1.7 while on a shopping trip, 1.5 each while watching a Game of Thrones episode or a football match, and none at all while salsa dancing, fine dining or sharing a passionate kiss. 

For the research, Ford took one Focus RS and worked with Designworks to create the Buzz Car:

From concept, design and installation to software development and programming, the Buzz Car took 1,400 man-hours to create. Each “buzz moment” experienced by the driver – analysed using a real-time “emotional AI” system developed by leading empathic technology firm Sensum – produces a dazzling animation across almost 200,000 LED lights integrated into the car. The Buzz Car also features:

  • High-performance Zotac VR GO gaming PC
  • 110 x 500-lumen daylight-bright light strips
  • 82 display panels with 188,416 individually addressable LEDs

Driver state research

Researchers at the Ford Research and Innovation Center in Aachen, Germany are already looking into how vehicles can better understand and respond to drivers’ emotions. As part of the EUfunded ADAS&ME project, Ford experts are investigating how in-car systems may one day be aware of our emotions – as well as levels of stress, distraction and fatigue – providing prompts and warnings, and could even take control of the car in emergency situations.

“We think driving should be an enjoyable, emotional experience,” said Dr Marcel Mathissen, research scientist at Ford of Europe. “The driver-state research Ford and its partners are undertaking is helping to lead us towards safer roads and – importantly – healthier driving.”

Activity Buzz Moments *
Roller Coaster 3
Driving 2.1
Shopping 1.7
Game of Thrones 1.5
Football Game 1.5
Kissing 0
Salsa Dancing 0
Dining 0

* Average number of high-intensity buzz moments per participant

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Cars

Car that sees round corners

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Jaguar Land Rover is leading a £4.7 million (approximately R79 million) project to develop self-driving cars that can ‘see’ at blind junctions and through obstacles.

Britain’s biggest carmaker is leading a project called AutopleX to combine connected, automated and live mapping tech so more information is provided earlier to the self-driving car. This enables automated cars to communicate with all road users and obstacles where there is no direct view, effectively helping them see, so they can safely merge lanes and negotiate complex roundabouts autonomously.

Chris Holmes, Connected and Autonomous Vehicle Research Manager at Jaguar Land Rover said: “This project is crucial in order to bring self-driving cars to our customers in the near future. Together with our AutopleX partners, we will merge our connected and autonomous research to empower our self-driving vehicles to operate safely in the most challenging, real-world traffic situations. This project will ensure we deliver the most sophisticated and capable automated driving technology.”

Jaguar Land Rover is developing fully- and semi-automated vehicle technologies, offering customers a choice of an engaged or automated drive, while maintaining an enjoyable and safe driving experience. The company’s vision is to make the self-driving car viable in the widest range of real-life, on- and off-road driving environments and weather.

AutopleX will develop the technology through simulation and public road testing both on motorways and in urban environments in the West Midlands. Highways England, INRIX, Ricardo, Siemens, Transport for West Midlands and WMG at the University of Warwick join the AutopleX consortium, which was announced as part of Innovate UK’s third round of Connected and Autonomous Vehicle Funding in March 2018.

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