Ford is developing a new form of manufacturing technology that has the potential to reduce costs and delivery times for sheet-metal parts needed in smaller quantities.
The Ford Freeform Fabrication Technology (F3T) — a patented manufacturing process developed at the Ford Research and Innovation Centre — sees a sheet-metal blank (clamped around its edges) formed into a 3-D shape by two stylus-type tools working in unison on opposite sides of the sheet. After the CAD data of a part is received, computer-
generated tool paths control the F3T machine to form the sheet metal part into its final shape — to the required dimensional tolerances and surface finish.
Traditional stamping processes are energy-intensive, and it often takes several months for the first part to move from concept to production. While traditional processes remain the most efficient method for high-volume stamping, efficient low-volume production can be achieved with the flexibility that F3T offers.
Its benefits include: the elimination of ‘geometric specific’ forming dies, along with the high costs and long lead times associated with die engineering, construction and machining; the delivery of a sheet metal part within three days of the CAD model being received; and improved vehicle research and development processes, allowing more flexibility in quickly creating parts for prototypes and concept cars.
Randy Visintainer, the director of Ford Research and Innovation, said: “The F3T sheet-metal-forming process is one of many advanced manufacturing technologies under development at Ford. We developed this process during the past four years for small-scale applications in a laboratory setting. Next, we will scale it for larger applications and a full prove-out for manufacturing feasibility.”