3D Printing

Serial merchandise in 16 weeks: An Aptiv and Quick Radius success story



Aptiv is a worldwide know-how firm that develops safer, greener, and extra related options to allow the way forward for mobility. They had been answerable for the design and manufacturing of a trailer-tow connector cap for Ford Tremendous Responsibility vehicles to guard {the electrical} connectors from harsh environmental publicity.

The problem

Aptiv wanted to push the boundaries of what’s doable in lower-volume, vital half manufacturing. The duty was to develop a trailer-tow connector cap that will meet Ford’s expectations for the absolute best price and speedy, versatile manufacturing.

The trailer-tow connector cap wanted to fulfill the automotive trade’s commonplace engineering and high quality necessities — particularly, USCAR-2 validation and ISO 9000 certification — to ensure the safety of {the electrical} connector in opposition to exterior parts and keep a seal at 105 levels celsius.

To make this doable, Aptiv labored carefully with Carbon, a pacesetter in digital manufacturing know-how and additive supplies improvement, and Quick Radius, a producing companion with experience in repeatable, dependable additive manufacturing. The collaborative effort led to the serial manufacturing of the trailer-tow connector cap for the Ford Tremendous Responsibility vehicles utilizing Carbon Digital Mild Synthesis™ (DLS™) know-how. Moreover, Aptiv’s additive manufacturing technique supplied a tool-free method, dashing time-to-market by 16 weeks in comparison with conventional molding options.

Making it doable

Trusted supplies for automotive purposes

This venture was Aptiv’s first automotive manufacturing utility to leverage additive polymer know-how. The Carbon crew labored carefully with Aptiv to decide on the precise materials to fulfill the product’s USCAR and degree 3 sealing necessities. After cautious analysis, Carbon EPX 82 was chosen as the best materials to supply the trailer-tow connector cap due to its temperature resistance, sturdiness, and power.

Industrial-grade digital manufacturing know-how

Carbon DLS know-how met Aptiv’s expectations for quick, dependable, and scalable manufacturing. With such rigorous trade necessities, Carbon DLS was the most effective methodology for the venture primarily based on the estimated manufacturing for scale. As soon as the know-how and supplies had been locked, Aptiv turned its focus to the connector cap’s design, collaborating with Quick Radius and Carbon engineers to optimize the design for manufacturing.

Manufacturing optimisation and experience

Printing hundreds of components repeatedly and reliably at scale with additive manufacturing generally is a problem. To make sure manufacturing reliability, Quick Radius leveraged their data of and expertise with Carbon’s know-how, additionally drawing on insights gained from their proprietary digital thread software program to design a construct file that optimally positioned the components on the construct plate. This might account for refined variances in temperature and lightweight variation.

High quality administration system for additive manufacturing

After an in depth on-site audit course of, Quick Radius turned the primary serial-approved exterior additive manufacturing provider for Aptiv within the automotive trade. Quick Radius relied on its additive manufacturing experience and software-backed digital thread capabilities to conduct and go a Manufacturing Half Approval Course of (PPAP). For manufacturing with Carbon DLS know-how, Quick Radius instituted part-specific commonplace working procedures throughout every step of the method and developed a rigorous management plan to make sure ongoing high quality.

The outcomes

The mixture of Carbon’s main digital manufacturing know-how and trusted supplies, together with Quick Radius’s additive manufacturing experience and infrastructure, made it doable for Aptiv to attain their progressive resolution. Finally, Ford confirmed that Aptiv and the broader crew executed a profitable launch of this product.

In the present day, the digital information for this product are saved within the Quick Radius Digital Warehouse™️ and ordered on-demand and printed as wanted. Along with Quick Radius and Carbon, Aptiv used the advantages of digital manufacturing to scale back tooling bills, get to market quicker, and supply a long-term, streamlined resolution to creating Ford’s trailer-tow connector cap with an additive know-how.

Put our supplies to the check

When in comparison with different 3D printing applied sciences like SLS, SLA, and conventional DLP, the Carbon Digital Mild Synthesis™ printing course of and patented dual-cure supplies are in a category of their very own.

Uncover what a Carbon 3D Printer is able to by requesting a free automotive pattern package now.

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