3D string in carmakers' bow

Tata Motors and Ford are eyeing first mover advantage in embracing a futuristic printing technology

The auto industry is witnessing a transformation of a kind that it has not experienced in several decades — from ownership models, electric and hybrid vehicles operating in a connected ecosystem to autonomous vehicles on the one hand, and a shift to stricter regulatory regimes around emissions, safety and sustainability on the other. These developments call for experimenting with emerging technologies to help automakers keep pace with growing customer demand for a customised and personalised experience.
 
With advances in 3D printing, a select few automakers are taking the leap of faith and exploring potential applications for personalisation of vehicles and for manufacturing light-weight car parts. Automakers as such are not new to 3D printing. A number of players have been using 3D printing over the years in the research and development (R&D) set-up for creating auto parts, testing and validating — both for engineering and design processes. However, with the recent advancement of material technology as well as cost optimisation (around both the materials as well as equipment) 3D printing has come to the fore in more end user scenarios.

 
Globally, Tata Motors and Ford Motor Company are making huge investments in 3D printing and are clearly eyeing the first mover advantage by embracing futuristic technology.
 

Earlier this month, Tata Motors showcased a concept sports car under its sub-brand TAMO — RaceMo at the Geneva International Motor Show. The automaker used 3D technology to create rapid, highly detailed models of the RaceMo in multiple numbers to hand out to visitors at the show. The scale model was the replica of the actual car. “3D printing is a cost-effective method to test multiple designs, to enable product developers to identify design flaws at an early stage and take informed decisions on a particular design to be sent to production,” says Pratap Bose, head of design, Tata Motors.

 
Essentially, the use of 3D printing technology opens the possibility of a new level of designing and prototyping. It not only allows the user to choose from a wide variety of materials including plastics, metals, and alloys but also helps in making designing more flexible. It helps in the aesthetic design of vehicles and delivers on the working of a prototype in a record turnaround time.
 
According to Global Industry Analysts Inc., by 2020 the global market for 3D printing is expected to reach $9.6 billion. For the auto industry in particular, the key driving factor for greater adoption of the technology lies in the emerging trend towards “design and build for one”, where customers are looking at customised and unique solutions.

 
Globally, Ford is testing 3D printing of large-scale car parts using the Stratasys Infinite Build 3D printer. The company is currently exploring potential applications for future production vehicles such as Ford performance vehicles or for personalised 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,” says Ellen Lee, Ford technical leader for additive manufacturing research.
 
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, automakers 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 a lower cost.

 
With technology advances, 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.
 
Lee points out that 3D printing is a more cost-efficient way to produce parts only needed at low volumes, such as prototypes and specialised parts for race cars. Further, Ford is also looking at using the technology to make larger printed tooling and fixtures as well as personalised components for customers.
 
Even as 3D printing is evolving and coming of age, industry heads believe the technology offers more opportunities than challenges. Bose sums it up all when he says that with its current structure, supply chain and cost dynamics, the auto industry is not suited to seize opportunities such as distributed manufacturing, shorter runs of a single design, and higher level of collaboration at the end user to customise solutions to meet their specific needs. “However, technology solutions like 3D printing could change all this and revolutionise the way cars are made in the near future.”