New Materials and Processes for Additive Manufacturing in Automotive Applications

Ellen C. Lee, Matls & Mfg Research, Ford Motor Company Giuseppe Lacaria, Matls & Mfg Research, Ford Motor Company Harold Sears, Prototype Mfg Test and Dev, Ford Motor Company

QUALITY SAFE SMART GREEN

ONE Ford Pillars

Additive Manufacturing at Ford Longstanding Additive Manufacturing Capabilities

Almost 30 years of experience Global Rapid Manufacturing Centers in NA and EU Significant investment globally Broad range of applications, processes, and materials Enabler for Ford Global Product Development System

New Research Program in Additive Manufacturing Ford Research and Advanced Engineering Areas:

Materials development and evaluation printed performance and durability Innovation in printing processes and technologies Functional application focus

Near-, mid-, and long-term goals for AM

Integration of AM at Ford Ea

rly In

trod

uctio

n Evaluation of early technology

Used for basic rapid prototyping

Utilization at low volume

Visual, proof of concept Te

chno

logy

Dis

pers

ion More widespread

use

Embraced and integrated into design and prototyping phases

Multiple additive manufacturing technologies and materials Ad

vanc

ed U

se/E

xplo

ratio

n Functional testing

Tens of thousands of prototype parts

Production level parts from additively manufactured tooling

Exploration for manufacturing tools

New

Inno

vatio

n Complex, production level, additively manufactured tooling

Multi-functional and multi-material components

Direct production of end use, functional parts

Additively Manufactured Tooling Reduced lead time for tooling Reduced cost by up to 70% Metal forming

Hydroforming Stretch forming Stamping

Plastics / Composites molding Injection molding Compression molding Thermoforming

Injection mold tooling printed with Stratasys Digital ABS

New Technology and Materials Development Current challenges of AM

Speed / Cycle time Performance of AM produced components Limited materials

Leverage partnerships with technology providers Carbon3D

Redwood City, CA based startup Early Access Program

Began December 2014 Announced June 23, 2015

Continuous Liquid Interface Production (CLIP) technology

CLIP Technology

Source: Carbon3D

CLIP: Continuous Liquid Interface Production Speed

Harnessing Light + Oxygen Continuous projection of UV images

Performance Layerless process Material chemistry

Material Choice Elastomer

Damping Elastic

Semi-Rigid Plastic Rigid Plastic High Temperature Resistant Plastic

Source: Carbon3D

CLIP: How It Works

CLIP: Isotropy of Printed Components CLIP technology allows layerless build Isotropic properties

0%

20%

40%

60%

80%

100%

0%

20%

40%

60%

80%

100%

CLIP FDM

CLIP Materials: Engineering Resins

0 10 20 30 40 50 60 70 80 90 100

Tens

ile S

tress

Tensile Strain (%)

PA6+15GF25M

ABS

PP

TPO

Carbon3D High T Resin

Carbon3D Rigid Resin

Carbon3D Semi-Rigid Resin

Carbon3D Elastomer Resin

CLIP Case Study: Rubber Grommet for Focus Electric Material: Elastomer Grommets produced in less than one third of the time as traditional prototype parts Material properties more durable and closer to desired final properties

CLIP Case Study: Multi-Material, Functional Part Material: elastomer + rigid plastic Three printed parts, assembled Prototype produced quickly with new design capable of functional testing

CLIP Case Study: Printed Injection Mold Tooling Materials: High Temperature Resistant Plastic Injection mold tool direct print with fine feature

resolution Testing in progress

Tool performance Durability; number of cycles Injection molded part performance

semi-crystalline thermoplastics tool thermal gradients

Insert Material PP Crystallinity (%)

Al at 77F 44.11

Al at 43F 43.05

PA12 43.19

SLA 1 43.1

SLA 2 44.1

SLA 3 45.1

CLIP: Future Direction Materials Development

Engineering composites Reinforcements Nanoscale additives

Conductive materials Thermal Electrical

Validation of direct printed applications Materials durability Performance Cost and speed

Additive Manufacturing Research Summary Automotive requirements unique Challenges remain

Durability Material types and performance Speed

Design for Additive Manufacturing Additive manufacturing will significantly impact automotive manufacturing

Acknowledgments

Ford Giuseppe Lacaria Harold Sears Sean Fannin Natania Hortsch Julia Titarelli Victoria Sears Esra Kiziltas

Carbon3D Ananda Day Kristi Eveland Jason Rolland Justin Poelma Billy McCall Kai Chen Courtney Fox Matt Menyo

THANK YOU!

PresenterPresentation NotesHenry Ford created Ford Motor Company in 1903. Even in the early years, he was focused on innovation and making mobility more accessible. Ford wanted to open the roads to all mankind and to make automobiles more accessible Ford was helping to pave those roads, literally. Yes, we are an automobile company but we Go Further than that and firmly believe in our responsibility to help make our world a better one.

A vision to build great products, a strong business and a better world, comes to life in our four pillars.

New Materials and Processes for Additive Manufacturing in Automotive ApplicationsONE Ford PillarsAdditive Manufacturing at FordIntegration of AM at FordAdditively Manufactured ToolingNew Technology and Materials DevelopmentCLIP TechnologyCLIP: Continuous Liquid Interface ProductionCLIP: How It WorksCLIP: Isotropy of Printed ComponentsCLIP Materials: Engineering ResinsCLIP Case Study: Rubber Grommet for Focus ElectricCLIP Case Study: Multi-Material, Functional PartCLIP Case Study: Printed Injection Mold ToolingCLIP: Future DirectionAdditive Manufacturing Research SummaryAcknowledgmentsSlide Number 18