When it comes to designing and developing a brand new car from the ground-up, automakers usually need about five years and approximately a billion dollars. Much of this development time is spent trying and testing intricate new components, which at one time had to be hand-assembled, a time-consuming procedure that can add months or even years to a vehicle deadline.
But with the increasing popularity of 3D printing, Ford and other automakers have been able to accelerate the design process, often able to take designs from the computer to the printer in a day or less, allowing for immediate testing and verification. In an increasingly fast-paced world, the importance of 3D printing is only beginning to be understood.
Ford has actually used 3D printing since 1988, acquiring the third 3D printer in the world to help it develop future vehicles. Today, 3D printers can be found in many homes (with adoption of home printers accelerating rapidly), and while these consumer-grade printers are still fairly basic, Ford has access to machines that are both rapid and accurate, creating individual layers thinner than a single piece of paper.
This accuracy is absolutely necessary for properly developing components like the Ford Mondeo’s intricate front grill. From computer to printer to finished part can take less than a day, allowing engineers to quickly determine whether or not that particular piece looks or works well enough for production. In the coming years 3D printing is likely to become even more commonplace within the auto industry, and it seems increasingly likely that we’ll see entire 3D printed cars within our lifetime.
You gotta admit, the future is pretty freakin’ amazing.