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Manufacturing Technology Insights | Tuesday, June 29, 2021
Nissan has shown its ability to expand its usage of 3D printing in all countries and for all automotive customers after successfully integrating the technology into its production process in its Barcelona factory
FREMONT, CA: BCN3D, a renowned 3D printing solutions provider in Spain, recently unveiled the new Nissan use case. Nissan has shown its ability to expand its usage of 3D printing in all countries and for all automotive customers after successfully integrating the technology into its production process in its Barcelona factory.
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The automaker has been creating tools, jigs, and fixtures for its manufacturing line in Spain using 3D FFF (Fused Filament Fabrication) technology from BCN3Dand the time and cost savings have been so impressive that it may soon roll it out to more manufacturing sites. So far, it has produced 700 parts, some of which cost as little as 3.45€ to produce.
Carlos Rellán Martínez, Manager of maintenance & engineering facilities at Nissan Motor Ibérica Zona Franca, Barcelona, says: “The performance achieved in terms of reliability has been excellent. Our printer runs nearly 24 hours a day and every year we are printing around 100 different jigs and tools for specific use in our processes. Outsourcing tools to a mechanical supplier was 20 times more expensive than 3D printing the same parts, while the wait for tools went from a week down to one day. By introducing 3D printing, we have increased added value and generated low costs, without high delivery times. We have paid off the investment in the printers very quickly.”
Nissan had previously outsourced all of its prototypes and jigs to mechanical vendors who employed traditional production techniques like CNC and drilling. The finished product was of good quality, but the lead times were long and rigid, and the expenses were exorbitant. For machining, even simple tools might cost up to 400 euros. Nissan has lowered its time to develop, refine, and produce some of these parts in-house with 3D printers from a week to just one day, slashing costs by 95 percent.
Additive manufacturing, or 3D printing, is becoming increasingly common in the automotive industry, allowing manufacturers to shorten development cycles and get vehicles into production faster. 3D printing also aids in reducing component production times while maintaining component quality.
“The automotive industry is probably the best example of scaling up a complex product with the demands of meeting highest quality standards. It is fascinating to see how the assembly process of a car - where many individual parts are put together in an assembly line - relies on FFF printed parts at virtually every stage. Having assembled thousands of cars, Nissan has found that using BCN3D 3D printing technology to make jigs and fixtures for complex assembly operations delivers consistently high quality components at a reduced time and lower cost,” adds Eric Pallarés, Chief Technical Officer (CTO), BCN3D.
Nissan’s additive manufacturing facility has a farm of four BCN3D printers, which have proven durability and can work 24/7, to keep up with Nissan’s demanding production schedule. In addition, Nissan can print two identical components simultaneously because of the printers’ Independent Dual Extrusion (IDEX) system, which effectively doubles production.
Nissan utilizes the BCN3D Smart Cabinet, a game-changing innovative solution designed to protect filament printability, extend shelf life, decrease aesthetic faults, and avoid costly reprints.A tool to fix a windshield centering gauge, a lower drill positioning tool, and a jig to position and cure the model name on the vehicle have all been created with BCN printers by the Nissan team. The fastening tool was made of TPU, cost 8€, and took 14 hours to print; the positioning tool was built of ABS, cost 21.50€, and took 15 hours to print; and the jig was made of ABS, costed 3.45€, and took 12 hours to print.
Nissan is now testing metal and printing 3D materials in plastic. Additionally, Nissan recently invited video cameras into its Barcelona facility for a rare look at how it uses 3D printing to produce final parts and prototypes on its assembly line for vehicles such as the Nissan Navara 4x4 pickup truck.
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