The automotive industry is rapidly transforming as consumer demands and regulatory pressures push for a shift from fossil fuels to electric vehicles, with Ford leading the way. Central to its European operations is Ford Cologne; and adjacent to this plant, PD Merkenich designs all passenger vehicles for the European market, including the new all-electric Explorer, which has recently begun production. To stay competitive and meet shorter development cycles, Ford utilizes PD Merkenich’s Rapid Technology Center for rapid prototyping in product development.
The Rapid Technology Center utilized Formlabs SLA and SLS 3D printers to quickly and cost-effectively prototype and validate designs, enabling the production of complex and functional parts for the new Explorer.
Watch a video about the process:
“Prototyping is very important in the development process,” said Sandro Piroddi, supervisor of the Rapid Technology Center at Ford, in a case study on the Formlabs website. “It gives you, the engineer, the possibility to verify the design.”
Formlabs SLA 3D printers, such as the Form 2, Form 3L and the latest Form 4, are used to create design prototypes requiring high surface quality and fast production for iterative testing.
For more complex designs, the self-supporting capabilities of SLS 3D printing are utilized, particularly with the Fuse 1+ 30W. This technology allows the production of intricate mechanical parts and assemblies, such as the charging cover for the Explorer, which require functional testing of mechanisms. Ford said that SLS 3D printing is the best solution for producing these parts, as traditional manufacturing methods like milling or injection molding are not viable for creating prototypes in small quantities.
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