3D printed production aids
Until now, 3D printing has mostly focused on creating functional prototypes and components. However, in car manufacturing, its real value is in making special tools, guides, masks and other aidsFull customization
3D printing technology can build complex geometric shapes with cavities, cuts, and recesses. Earlier designs of eyeliners or mascaras were impractical, but now they are becoming a viable option; functionality and performance become the main design criteria, not cost or time.
Expedited delivery
Machining tools for production takes several weeks, especially if there are several different solutions. Printing parts on demand speeds up the manufacturing and delivery process. Production using the Ultimaker 3D printer reduces the realization time between 40% and 90%.
Unlimited use
No manual or mechanical processing is required to make the model. If there is a problem with the current tool or an improvement is suggested, manufacturing a replacement part involves editing the existing CAD file and printing the improved part. The costs are much lower compared to traditional manufacturing methods, and the final product can be customized in detail. Functionality and design are compared to the actual part, and new tests can be performed within hours at no additional cost.
Economy
"Now we have many more tools, better adapted, and for incomparably less money. By printing just a few pieces of tooling, we can recoup the initial investment.” - Luis Pascoa, Pilot Plant Manager at Volkswagen Autoeuropa
Innovative ways to make tools
The Ultimaker 3D printed tool has improved performance. Tool manufacturing time was shortened from 54 days, and costs were reduced by 2,813 euros. The tools are ergonomic, solid, and light. Traditionally, tools would be precision machined, with associated costs, manufacturing time, would be heavier and require special storage space. In some cases, manufacturers often got by without the right tools - to the detriment of process control.
Case study: Volkswagen Autoeuropa
By using 3D printing, they reduce costs, time and labor for the production of tools, guides and mascara. By using 3D printed tools, guides and masks, Volkswagen Autoeuropa significantly reduces the cycle time of operations, labor, waste, and the need for refinishing, all while improving the ergonomics of the tool. What's more, all this was achieved for a tenth of the usual cost.
Volume of production
Volkswagen Autoeuropa currently manufactures the Volkswagen Sharan (53,423 units), Scirocco (16,251 units), Eos (4,559 units), and Seat Alhambra (27,925 units).Challenges
Before the cooperation with Ultimaker, Volkswagen Autoeuropa used independent suppliers for the production of tools. This meant more paperwork, price reconciliation, but also accepting a trial and error approach, which all together slowed down the production process - with additional costs.The solution
Volkswagen Autoeuropa started using Ultimaker 3D printers in 2014. Within just two years, assembly tool cost savings increased from 70% to 95%. Ultimaker enabled VW Autoeuropa to test new solutions immediately, without contacting suppliers, which shortened the entire process by an average of eight weeks.Results and return on investment
After the concept proved successful in 2014, VW Autoeuropa now has 7 Ultimaker 3D printers and 93% of all externally produced tools are now produced on site. Externally produced parts now make up only 7% of their total tool production, and the investment is covered by printing just a few tools. It is estimated that the company saved 150,000 euros in 2016 with the goal of saving 250,000 euros in 2017.
APPLICATION
Ultimaker's system that integrates hardware, software and materials allows production to begin the moment the machine is installed.- Manufacturing Process Oversight - Manufacturing engineers, CAD designers and technicians oversee manufacturing and process quality. Thus, new ideas and solutions for 3D printed guides, switches and mascaras are created on the spot.
- Everyone is involved in the process - Staff who constantly use the tools are involved in development. Their contribution is invaluable, since they are the ones who use the tools on a daily basis. The printers are placed next to the assembly line so the tools can be used immediately and any changes and improvements made.
- From design to production - Once the design is conceived, a CAD file is prepared, processed in CURA, then sent to a 3D printer that runs overnight and the next morning the new tool is ready for use.
- Installation and Revision - Additive manufacturing enables "just-in-time" inventory production, where digital design files are stored and spare parts are modified and printed as needed. Incorporating 3D printers into production improves quality, ergonomics and efficiency, saving money.