{"id":11699,"date":"2019-02-05T14:55:14","date_gmt":"2019-02-05T14:55:14","guid":{"rendered":"https:\/\/www.3dnatives.com\/en\/?p=11699"},"modified":"2024-02-21T09:35:29","modified_gmt":"2024-02-21T08:35:29","slug":"ford-3d-printed-metal-part-050220195","status":"publish","type":"post","link":"https:\/\/www.3dnatives.com\/en\/ford-3d-printed-metal-part-050220195\/","title":{"rendered":"Ford produces the largest ever 3D printed metal automotive part"},"content":{"rendered":"

Largest 3D Printed Metal Automotive Part in History<\/h3>\n

Ford Performance, the high-performance division of Ford Motor Company, 3D printed what they claim to be the largest metal automotive part for a working vehicle in automotive history. The metal part was installed in the Hoonitruck, a 1977 Ford F-150 with a twin-turbo 3.5-litre V6 EcoBoost engine owned by Ken Block, star of popular YouTube series, Gymkhama.<\/p>\n

\"Ford<\/h3>\n

Apart from revealing that the part is 6kg in weight and took five days to print, Ford did not reveal the exact measurements of the part. We know that it is an aluminium manifold inlet, printed by the XXL printer from GE Additive: the Concept Laser X LINE 2000R<\/a>.<\/p>\n

If it is in fact the largest metal additively manufactured part, then it must be bigger than Bugatti\u2019s 3D printed brake caliper<\/a>. Bugatti also claimed their part to be the largest functional titanium component when it was printed; it measured 41 x 21 x 13.6 cm.<\/p>

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Ford Performance, based in Michigan, collaborated with a team of research engineers based in Europe to design and conduct structural analysis. Then, the part was manufactured at Ford\u2019s German 3D printing lab with the help of RWTH Aachen\u2019s Digital Additive Production Institut, from Aachen University in Germany.<\/p>\n

Complex Design and Structure<\/h3>\n

Raphael Koch, engineer in Advanced Materials and Processes at Ford Europe said, \u201cWe are fortunate to have access to incredible technology, but this was one project that pushed us \u2013 and our computing power \u2013 to the absolute limit. The manifold has a complex web\u2011like structure that couldn\u2019t be made using traditional manufacturing methods. We ended up dissolving the support systems in acid\u201d<\/em>.<\/p>\n

The intake manifold is a hard part to manufacture and represents an important part of a car, particularly a racing vehicle. Uneven air distribution and other engine performance problems are common when designing this part. Additionally, the part involves many other small components in order to be put together.<\/p>\n

Nevertheless, Ford was capable of producing a manifold printed into a webbed structure with the use of aluminium alloy powder thanks to metal additive manufacturing<\/a>.<\/p>\n

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Custom 1977 Ford F-150 for a Youtube Series<\/h3>\n

The vehicle is a 1977 Ford F-150 converted into a custom truck, the Hoonitruck. Ken Block, star of the popular YouTube automotive racing series Gymkhana, built it 2014 after two years of development.<\/p>\n

Block stated, \u201cI think Ford did an exceptional job. This is my favourite part of the Hoonitruck. You could not have made it any other way.<\/em>\u201d<\/p>\n