QuickCast™ &amp; Rapid Tooling: A Case History at Ford Motor Company

doi:10.15781/t26q1t23t

Study

Final ProductionHigh ImpactStrong effect

Stereolithography Accuracy Improves Dramatically, Enabling Functional Prototypes

Advancements in stereolithography technology have significantly improved part accuracy and material properties, moving beyond simple visualization to enable the creation of functional prototypes.

Texas ScholarWorks (Texas Digital Library) · 2018

01

Key Findings

01Early stereolithography parts were brittle, inaccurate, and had poor surface finish, limiting their use to visualization.
02Significant advancements in technology have led to a dramatic improvement in the accuracy of stereolithography parts, with the '90th percentile error' decreasing substantially over time.
03Improved accuracy and material properties have enabled stereolithography to move beyond visualization and be used for functional prototyping and tooling.

02

Application

Design takeaway

Leverage advanced rapid prototyping techniques like stereolithography for functional testing of prototypes, not just for visual assessment, to de-risk designs and speed up development.

How to apply

When developing new products, consider using advanced rapid prototyping methods to create functional prototypes that can undergo real-world testing before committing to expensive tooling and final production.

Project actions

01When planning your design project, consider how rapid prototyping can be used not just for aesthetics but for functional testing.
02Research the latest advancements in 3D printing technologies relevant to your project's material and performance requirements.

03

Method & Evidence

AimTo investigate the historical development and impact of stereolithography (SL) on the accuracy and utility of rapid prototyping parts, particularly in the automotive industry.

MethodCase study and historical analysis

ProcedureThe paper traces the evolution of stereolithography technology from its inception, detailing improvements in hardware, software, resin formulations, and process methods. It presents data on the improvement of a key accuracy metric (epsilon ninety) over time and discusses the shift in the primary application of RP&M parts from visualization to functional prototyping.

ContextAutomotive manufacturing and rapid prototyping

Variables

IVAdvancements in stereolithography technology (hardware, software, materials, process methods)

DVAccuracy of printed parts (e.g., epsilon ninety), utility of parts (visualization vs. functional prototyping)

CVSpecific stereolithography machine models, resin types used, 'UserPart' accuracy test methodology

04

Strengths & Limitations

Strengths

+Provides a historical perspective on technological development.
+Quantifies improvements in accuracy over time.

Limitations

The specific accuracy improvements and material capabilities may vary significantly between different stereolithography machines and materials. The 'UserPart' test may not perfectly represent the accuracy required for all applications.

Reliability & validity

The study's findings on accuracy improvement are based on a specific metric ('epsilon ninety') and test ('UserPart'). The validity for other applications depends on how well this metric and test represent real-world functional requirements. The historical data provides a basis for reliability in tracking technological progress.

Think critically

How might the continued improvement in rapid prototyping accuracy and material science further disrupt traditional manufacturing processes and product development timelines?

05

Design Principles

"Iterative design validation through functional prototyping is critical for product success."

This evolution in rapid prototyping allows designers and engineers to test and validate designs with greater fidelity, reducing the risk of errors and accelerating the product development cycle. It bridges the gap between conceptualization and final production by providing tangible, testable models.

06

What This Means for Your Design

Old 3D printing was only good for looking at, but new 3D printing is accurate enough to actually test how parts work before making them.

How to use in your project

1.Reference this case study when discussing the evolution of prototyping technologies and how improved accuracy enables functional testing in your design project.
2.Use the findings to justify the selection of a specific prototyping method for testing critical design features.

07

Add to My Project

08

Quick Cite

(2018). QuickCast™ & Rapid Tooling: A Case History at Ford Motor Company. Texas ScholarWorks (Texas Digital Library). https://doi.org/10.15781/t26q1t23t Retrieved from https://designdex.org/study/8e7bb1cb-8f10-4d2e-a5d9-17d7558a26d1/stereolithography-accuracy-improves-dramatically-enabling-functional-prototypes

Paragraph starter

The evolution of rapid prototyping technologies, particularly stereolithography, has seen a significant increase in part accuracy and material robustness. As highlighted by case studies like Ford's QuickCast™ development, advancements have moved beyond simple visualization to enable the creation of functional prototypes. This enhanced fidelity allows for more rigorous testing and validation of design elements prior to final production, thereby reducing development risks and accelerating innovation.

09

Source

Texas ScholarWorks (Texas Digital Library)

QuickCast™ & Rapid Tooling: A Case History at Ford Motor Company

journal · 2018

View source

Questions about this research

What does the research say about stereolithography accuracy improves dramatically, enabling functional prototypes?: Leverage advanced rapid prototyping techniques like stereolithography for functional testing of prototypes, not just for visual assessment, to de-risk designs and speed up development. Evidence: Texas ScholarWorks (Texas Digital Library) (2018).
Why does "Stereolithography Accuracy Improves Dramatically, Enabling Functional Prototypes" matter for design?: This evolution in rapid prototyping allows designers and engineers to test and validate designs with greater fidelity, reducing the risk of errors and accelerating the product development cycle. It bridges the gap between conceptualization and final production by providing tangible, testable models.
How can designers apply this research?: Leverage advanced rapid prototyping techniques like stereolithography for functional testing of prototypes, not just for visual assessment, to de-risk designs and speed up development.
What were the main findings?: Early stereolithography parts were brittle, inaccurate, and had poor surface finish, limiting their use to visualization.. Significant advancements in technology have led to a dramatic improvement in the accuracy of stereolithography parts, with the '90th percentile error' decreasing substantially over time.. Improved accuracy and material properties have enabled stereolithography to move beyond visualization and be used for functional prototyping and tooling.
What research method was used?: Case study and historical analysis.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2018 journal from Texas ScholarWorks (Texas Digital Library).
What should I do differently in my next project?: When developing new products, consider using advanced rapid prototyping methods to create functional prototypes that can undergo real-world testing before committing to expensive tooling and final production.
What are the limitations?: The paper focuses on stereolithography and may not represent the full spectrum of rapid prototyping technologies. Specific material properties and performance under extreme conditions are not detailed.
Is there evidence that just visual affects design outcomes?: Stereolithography technology has matured significantly, with accuracy improving from hundreds of micrometers to much finer tolerances, allowing for the creation of functional parts rather than just visual models. This evolution in rapid prototyping allows designers and engineers to test and validate designs with greate Source: Texas ScholarWorks (Texas Digital Library) (2018).
Where does this rapid prototyping research apply?: Automotive manufacturing and rapid prototyping It sits within final production research on designdex.org.