Part of a 3D printed engine cover on the Toyota build platform. (Source - Zortrax).

Japanese multinational car company Toyota has revealed how the adoption of 3D printing has helped streamline its car assembly operations. 

At its two Polish plants in Walbrzych and Jelcz-Laskowice, Toyota switched from CNC machining of mounting fixtures to manufacturing them using on-demand systems, via 3D printers. In this way, the automotive leader was able to reduce costs and lead times behind the production of essential tools and spare parts in a way that optimized the productivity of its production line. 

“We don't have to stock spare parts because we can 3D print them on demand. We can start a 3D printing process when the need arises," explains Łukasz Kondek, the engineer in charge of 3D printing at Toyota. “We don't have to wait until our tooling department (or outsourcer) has the capacity to take care of our orders. 3D printing cuts the wait time for the necessary tools from weeks to days or sometimes even hours.” 

"WE CAN OPTIMIZE OUR DESIGNS FREELY BECAUSE 3D PRINTERS MATERIALIZE ALMOST ANY GEOMETRY YOU CAN IMAGINE."

The exploits of Toyota's Polish 3D printing 

Much of the work at Toyota's factories in Poland revolves around fitting engines into the cars it assembles and then sells in Europe. The facilities, where more than 3,000 employees now work on Toyota gasoline and hybrid vehicles, house specialized 3D printing laboratories that have installed equipment worth more than 100,000 zlotys ($23,000). 

For years, engineers at Toyota's Polish facility have implemented 3D printing in applications for manufacturing templates, tools and spare parts. The parts currently being 3D printed at the company's facility fall into four categories: positioners, assembly fixtures, assembly tools, and covers. Once printed, they are often combined with other components created using subtractive technologies to form integrated modules. 

For example, the appliances used in some Toyota cars have a 3D printed body. However, because the pins on these tools are in continuous contact with a metal surface, they are now CNC machined in a way that improves their durability. 

Additionally, Toyota's assembly line templates were previously produced by a separate shop equipped with CNC machines. As a result, the company's engineers had to design these tools around the limitations imposed on them by traditional manufacturing technologies. Since switching to 3D printing, however, Toyota has been able to reduce its lead time and minimize assembly line disruption. 

The car manufacturing process at Toyota. (Source - Zortrax).

"One of the key advantages of implementing 3D printers in manufacturing and industry is their tried and true, robust construction and easy maintenance," adds Michał Siemaszko, head of R&D. "This means global manufacturers like Toyota can rely on them while printing equipment that is critical to keeping the assembly line running."

“RELIABILITY IS ESSENTIAL AS EVEN SHORT DELAYS CAN GENERATE LOSSES THAT FAR EXCEED THE VALUE OF THE PRINTERS THEMSELVES. THEREFORE WHAT WE OFFER LARGE INDUSTRIAL CUSTOMERS IS CONFIDENCE.”

AM in Automotive Fixtures, Tools and Templates

Toyota is far from the only automaker to 3D print templates, fixtures and tools, and the technology continues to gain traction in the automotive industry. In 2021, it was announced that Audi is now using more EOS-3D printed tools at its Metal 3D Printing Center in Ingolstadt, where models such as the A4 sedan are assembled. 

3D printed template (Source - Zortrax).

In the same year, it was also revealed that Skoda is implementing 3D printing in automotive spare parts manufacturing, prototyping and tooling applications. As part of its plans to double down on digitization in its production facilities, the company has set up several print farms featuring systems developed by popular print brands. 

Elsewhere, using ExOne binder jetting, FreeFORM Technologies has 3D printed tools for the automotive industry as well. In the past, the company has 3D printed a complex end-of-arm tooling component for Allegheny Electric Service, which in turn attached it to a six-axis FANUC robot as part of a parts inspection system.


0 Comments

Leave a Reply

Your email address will not be published. Required fields are marked *

en_USEnglish