DEARBORN, Mich. The Ford Motor Company has developed a new technology that rapidly forms sheet metal parts for low-volume applications.
Known as the Ford Freeform Fabrication Technology (F3T), the patented manufacturing process was developed at the Ford Research and Innovation Center, in Dearborn, Michigan.
The process works by clamping a piece of sheet metal and forming a 3D shape with two stylus-type tools working in unison on opposite sides of the metal blank. CAD data is received, then computer-generated tool paths control the machine, forming the sheet metal into its final shape and surface finish.
As a result, the need for geometric-specific forming dies is eliminated, as is high cost and long lead time associated with die engineering, and machining.
Traditional stamping processes also require a lot of energy, but are still the most efficient method for high-volume production.
The company is going to use the technology primarily for prototyping, and once fully developed, the technology will lead to lower costs. The delivery of prototyped parts will also be substantially reduced, making them available within a few days versus the usual two months or longer approximately 60 times longer than the F3T turnaround time.
In addition to quickly creating parts for prototypes and concept cars, other applications could include aerospace, defence, transportation and appliances.
As we forge ahead with cutting-edge technologies in manufacturing like flexible body shops, robotics, 3D printing, virtual reality and others, we want to push the envelope with new innovations like F3T to make ourselves more efficient and build even better products, states John Fleming, executive vice president, global manufacturing and labor affairs.
The F3T sheet metal forming process is one of many advanced manufacturing technologies under development at Ford, said Randy Visintainer, director of Ford Research and Innovation.
We developed this process during the past four years for small-scale applications in a laboratory setting, and the DOE award enables us to scale the process for larger applications and a full prove-out for manufacturing feasibility.
The project is part of a three-year, $7.04 million U.S. Department of Energy grant to advance next-generation, energy-efficient manufacturing processes.
