Japanese automotive multinationalToyota已经揭示了如何采用Zortrax3D printing has helped optimize its vehicle assembly operations.
丰田在其在沃尔布尔兹（Walbrzych）和耶尔克斯·拉斯卡（Jelcz-Laskowice）的两个波兰设施中，从CNC加工组装夹具和固定装置切换为使用Zortrax M300 Plussystems on-demand. In doing so, the automotive stalwart has managed to reduce the costs and lead times behind manufacturing essential tools and spares, in a way that has optimized its production line performance.
“我们不必存储备件，因为我们可以按需3D打印它们。每当发生这种需求时，我们都可以开始一个3D打印过程。”“我们不必等到我们的工具部门（或外包商）有能力照顾我们的订单。3D打印可以缩短需要工具的等待时间，从几周到几天，有时甚至几个小时。”
“We can optimize our projects freely since 3D printers materialize nearly all geometries imaginable.”
M系列3D打印在Zortrax
当Zortrax于2018年推出了原始Inkspire系统时，Zortrax扩展到了树脂3D打印领域，但最著名的是融合细丝制造机（FFF）机器的制造商。在投资组合的这一侧，该公司提供Endureal,M200 Plus,M300 Dual， 和M300 Plus3D printers, each of which operates using its proprietary Layer Plastic Deposition Plus (LPD) extrusion technology.
Having installed the latter, Toyota has adopted the largest of the three, which thanks to its 300 x 300 x 300 mm build volume, is capable of creating huge parts in single prints. In practice, this means users don’t have to break large-format models down into separate pieces for assembly, something that can necessitate the integration of joints – weak spots that often impact long-term durability.
The system’s packaged farm management software also makes it particularly well-suited to deployment at scale, while its support for third-party filaments has lent it wide-ranging applications, including everything fromsolar energy product prototyping，制造独特的Cyberpunk-inspired cosplay outfits。
为了进一步提高其产品的功能，Zortrax还继续为其机器引入材料和升级。去年，该公司推出了新的“太空级”Z-PEEK 3D printing filament。从那以后，Zortrax启动了Full Metal Packages, which make metal 3D printing possible on the Endureal.
Toyota’s Polish 3D printing exploits
Much of the work at Toyota’s factories in Poland revolves around mounting engines into the cars it assembles and then sells in Europe. Housed inside the facilities, in which over 3,000 employees now work on both Toyota petrol and hybrid vehicles, are dedicated 3D printing labs that have installed more than 100,000 zł ($23,000) worth of Zortrax equipment.
For years, engineers at Toyota’s Polish facility have deployed the Zortrax M300 Plus in jig, tooling, and spare part production applications. The parts currently 3D printed at the firm’s plant fall into four categories: positioning jigs, assembly jigs, assembly tools, and covers. Once printed, these are often combined with other components created using subtractive technologies to form integrated assemblies.
对于instance, the gauges used in some Toyota vehicles feature a 3D printed body. However, as the pins on these instruments are continually in contact with a metal surface, they’re now CNC machined, in a way that improves their durability.
此外，丰田的装配线夹具以前是由配备CNC机器的单独部门制造的。结果，该公司的工程师必须设计这些工具，围绕传统制造技术对它们施加的约束。但是，自从切换到3D打印以来，丰田已经能够减少其交货时间并最大程度地减少装配线破坏。
“One of the key benefits of implementing Zortrax 3D printers in manufacturing & industry is their tried and true, stable construction and ease of maintenance,” adds Michał Siemaszko, Head of R&D at Zortrax. “That means that global manufacturers like Toyota can rely on them while printing equipment critical to keeping the assembly line running.”
“Reliability is essential, as even short delays can generate losses that far exceed the value of the printers themselves. Therefore, what we offer large industrial customers is assurance.”
AM in automotive jigs, tools and fixtures
Toyota is far from the only car manufacturer that’s 3D printing jigs, fixtures, and tooling, and the technology continues to gain ground in automotive. In 2021, it was announced that奥迪now uses more EOS-3D printed tooling在Ingolstadt的金属3D打印中心，在那里组装了A4轿车之类的型号。
那年，也揭示了Skoda deploys 3D printing in automotivespare part production, prototyping, and tooling applications. As part of plans to double down on digitization at its manufacturing facilities, the company has set up several print farms featuring systems developed by popular printing brands likePrusa。
Elsewhere, usingExOnebinder jetting,FreeFORM Technologies has 3D printed toolingfor the automotive industry as well. In the past, the firm has 3D printed a complex end-of-arm tooling component forAllegheny电力服务, which in turn, attached it to a six-axisFANUCrobot as part of a part inspection system.
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Featured image shows the automotive production process at Toyota. Photo via Zortrax.
