Sheet metal forming prototyping machine

[Will M]

Ford Freeform Fabrication Technology (F3T)

Below are links to an article and a video for a new process that Ford made for making stamped metal prototypes.
While not inherently related to FSAE it could become a useful process in the future.

http://www.youtube.com/watch?v=Wl5_wUVxRvw&hd=1

http://www.slashgear.com/ford-...gear+%28SlashGear%29 (http://www.slashgear.com/ford-f3t-technology-cuts-prototype-process-to-three-business-days-03288902/?utm_source=feedburner&utm_medium=feed&utm_campaign=Feed%3A+slashgear+%28SlashGear%29)

Pro:
Make complex sheet metal parts in a few hours
Requires no tooling investment beyond the first machine
Ideal for low volume and custom parts

Con:
Takes hours
Very expensive
Limited size

-William
(edit: links)

[Kirk Feldkamp]

Wow. That's awesome! "Expensive" is clearly a relative term. Have you ever quoted prototype stamp tooling? It's usually not too far off from production tooling, and will usually take 6-20 weeks depending on the vendor. If this sort of thing becomes available outside of Ford, it could be a huge step forward for a lot of different industries.

[onemaniac]

That is quite amazing.

[Will M]

I honestly don't know how much stamping dies cost, but I know the machines themselves are super expensive.

This system really wouldn't be that expensive.
It is just two Fanuc F-200iB robots, a frame and a controller.

http://www.fanucrobotics.com/c...200iB%20Series_9.pdf (http://www.fanucrobotics.com/cmsmedia/datasheets/F-200iB%20Series_9.pdf)

However, the research needed to build one (and figure out the software) would be intensive.

I've read about big automotive presses that cost in the range of 40 to 50 million USD.
This system could be built to probably under one million, certainly two.
Fanuc also has robots big enough to do an entire side panel, or fsae monocoque panel http://fsae.com/groupee_common/emoticons/icon_smile.gif, but they are less accurate.


-William

[jlangholzj]

Originally posted by Will M:
I honestly don't know how much stamping dies cost, but I know the machines themselves are super expensive.

This system really wouldn't be that expensive.
It is just two Fanuc F-200iB robots, a frame and a controller.

http://www.fanucrobotics.com/c...200iB%20Series_9.pdf (http://www.fanucrobotics.com/cmsmedia/datasheets/F-200iB%20Series_9.pdf)

However, the research needed to build one (and figure out the software) would be intensive.

I've read about big automotive presses that cost in the range of 40 to 50 million USD.
This system could be built to probably under one million, certainly two.
Fanuc also has robots big enough to do an entire side panel, or fsae monocoque panel http://fsae.com/groupee_common/emoticons/icon_smile.gif, but they are less accurate.


-William

but with the 200 having a repeatability of +/- 0.1 mm....how accurate is "accurate enough" to make a FSAE tub?

this is some seriously cool stuff. Another avenue that I can see this going towards are one-off molds. design and test fit the piece with AL/A36 and then form the mold and lay up carbon for final testing.

Another thing someone hasn't mentioned yet: Fuel tanks! There's some seriously cool shapes you could tackle with this (for increased packaging).

[BrendonD]

This thing has been in the works for years, I think I first heard of the concept in 2009. Very cool technology.

Also, 0.1mm = 0.004", that's pretty great for sheetmetal components.

[Will M]

@jlangholzj

If we are only talking suspension pick up point .1mm is an order of magnitude better than what our goal was for our car and I doubt we met our goal.
A bigger concern would be mating several formed pieces together.
For FSAE that would depend on your welding skill.
But I'd say .1mm is great http://fsae.com/groupee_common/emoticons/icon_wink.gif

However, that is the repeatability for the robot not for the part.
Their larger robots are closer to .3mm but as long as they don't crash into each other you should be fine.

If you can change the tool from the two ball points you could add other features.
(Think: punched holes, center punch marks for drilling, louvers, ect)

I love the idea of mold making!
But it wouldn't have to be a one-off; a steel or aluminum mold would be much better than most fiberglass 'production' molds.
It could be made in a few hours, require minimal polishing, and would last much longer.

-William

[Adambomb]

Wow, it's like a CNC English Wheel. Brilliant!