Sand Castles, Laser Printers Improve Fuel Economy, Cost and Reliability of Ford Vehicles
Topic: Auto News
While Ford Motor Company's new Beech Daly Technical Center may be the most sophisticated prototyping complex in the industry, the mediums they use may not seem like the stuff of rocket science. Sand castles, laser printers, and candle wax are used to quickly and efficiently build prototype parts used to test every nut and bolt on a new car. Housed in a rather unassuming building in Livonia, Mich., the center is capable of casting, machining, assembling and testing every major powertrain component, faster and more efficiently than ever. Prototype components are used in every stage of vehicle development, with the intent of making the product more reliable, more fuel-efficient, and more affordable for the consumer. The BDTC facility's rapid prototyping brings these benefits to the consumer faster, and more economically than ever. Five years ago, the time required to turn computer-aided design data into a functioning engine prototype could require more than six months. Today, Ford plans to build the first prototype of an all-new engine program from scratch in just 10 weeks. For Ford, this quick reaction time is expected to cut one to two years off of the typical time required to bring a powertrain to market. In addition, rapid prototyping eliminates the expense of tooling previously required to make functional components. This saves up-front costs, and significant costs as the engineering process drives design change. For example, the tooling for a small engine component could cost as little as $10,000. However, if nine design changes are required through the program, the cumulative cost of tooling alone could be $100,000. These cost savings increase exponentially with larger, more complicated components, such as engine blocks, cylinder heads and intake manifolds. "We believe the Beech Daly center is the most advanced prototyping facility in North America," says Todd Kloeb, manager, Engine Manufacturing Development Organization. "Paired with our sister facility in Dutton, England, Ford Motor Company now has the most sophisticated prototyping organization in the world. The center features proprietary technologies, but our advantage is not just in hardware and equipment. Rather, it's how we deploy that technology for significantly faster, cheaper prototype production." The BDTC relies on six techniques to produce prototype components. Two rapid casting techniques produce functional metal components that replicate sand-cast or high-pressure die-cast production components. Four rapid prototype technologies replicate functional plastic components, or non-functional, design-aid replicas. Here, computer data is translated into molds, built out of sequential layers of sand. These molds would humble the most elaborate sand castles, as these precise sand molds are filled with molten metal to make functional prototype pieces, such as an engine block. A pre-mixed layer of sand and activator is first applied to the entire build platform. Next, a printhead squirts a binding mixture onto the layer of sand. The activator and binder harden, creating the sand mold, one layer at a time, from bottom to top. Once the excess sand is removed, the mold can be filled with molten metal to cast the prototype piece. This makes very accurate, very intricate metal prototypes, such as transmission valve bodies. The begins by producing a rapid prototype master directly from CAD data. A silicone mold of the master is then filled with wax to create a pattern. These wax patterns are then dipped in ceramic. However, these ceramic pieces are not meant for display on a kink-knack shelf. After the ceramic hardens, the wax is replaced with molten metal to cast the prototype piece. SLS is used to make functional plastic components. For example, technicians at the center used SLS to develop functional intake and velocity stacks for use on Ford Racing's championship-winning FR500C Mustang. The Selective Laser Sintering process involves the production of a physical model by melting specific sections of powdered material, layer by layer. Like a laserjet office printer, the SLS laser beam scans each layer on the powder bed to fuse the fine particles into a solid area. Another layer of powder is then deposited and the next layer of the part is drawn. The solid sintered material forms the part, while the loose material acts as a support. When the build is finished, the loose material is removed to reveal the prototype piece. (click here for related story) Stereolithography can produce a very accurate, very inexpensive replica of a component in plastic. These are not functional pieces, and are usually used for design aid, or engineering models. For example, SLA replicas of metal castings are used to verify machining patterns and tool paths before the expensive metal components are cut. SLA components are made by curing a photosensitive liquid resin, which forms a solid surface when exposed to an ultraviolet laser. Each layer of the part is scanned onto the resin surface. Once a layer has been scanned, the build platform is lowered below the surface of the resin, and the process is repeated. When the build is complete, the part is raised out of the liquid resin, cleaned, and fully cured. Car Reviews Concept Car Auto Insurance Tires Wheels

No-tools Prototyping Technology Saves Ford Millions
Sometimes, it's just as important to recognize a good idea and help bring it to fruition as it is to originate the concept. Such was the case a few years ago when Ford Motor Company learned of two experimental technologies at American universities - Selective Laser Sintering (SLS) and 3D Printing Sand - capable of producing prototype parts without expensive tooling. With Ford's help, those processes are at the forefront of rapid prototyping technologies, helping the company dramatically slash costs, improve time to market and better handle frequent product changes. "Those two technologies combined have saved millions of dollars since their launch just six to eight months ago," said Todd Kloeb, manager of Ford's Beech Daly Technical Center. "That doesn't include other benefits, such as much faster product development time and greater knowledge of the production processes necessary to mass produce the part." Ford's role in bringing SLS and 3D Sand Printing to the auto industry was to combine the materials experimentation in the U.S. with automation technology needed to utilize the materials being developed in Europe. Ford's Office of General Council navigated the legal waters, ultimately allowing Ford a head start on the competition. "Soon, other automakers will be able to use the technology, but because Ford did the leg work, we will have at least a year's advantage," Kloeb said. "These technologies completely revolutionize how we go through the product creation process. They are critical enablers of our new Global Product Development System." Both SLS and 3D Sand Printing literally grow prototype components in small sections, or slices, from a computer-aided design (CAD) model. Creating components this way results in extremely precise parts. In the case of SLS, a laser is used to sinter, or fuse, specific sections of powdered material. Three-Dimensional Sand Printing incorporates a print head - much like that used in inkjet printers - to distribute standard foundry binding material to layers of production sand. Unlike SLS, the print heads and build chambers are fully scalable and can be made as large as necessary to accommodate bigger components. Lasers become more difficult to manage once they reach a certain size. Both technologies are capable of producing production-ready components much faster than previous methods, at a fraction of the cost. "Three to five years ago, we would spend hundreds of thousands of dollars on a disposable prototype tool for a die cast part, and then wait a year to get the tooling to make the part," said Kloeb. "If we had subsequent changes to the part, that added more cost to change the tool and tacked on additional time to make each new part." Now, a prototype part can be produced within days of receiving the CAD drawing. The same goes for changes. The turnaround time is extraordinarily fast. And there are no prototype tool expenses. "These technologies can be leveraged in so many areas, such as to facilitate frequent changes," said Kloeb. "For example, every year, nearly all programs undergo changes to intake manifolds to accommodate new regulatory requirements. We can do that in a snap, now." Aircraft manufacturer Boeing already is using SLS to manufacture parts for some of the company's fighters. Kloeb says the technology could even be used on low-volume automotive products, such as the Ford GT. It becomes too expensive at higher volumes, though. According to Kloeb, Ford will launch another rapid prototyping technology in the first quarter of 2006 that will have just as much impact as SLS and 3-D Printing Sand. Car Reviews Concept Car Auto Insurance Tires Wheels

MAZDA TO INCREASE MZR ENGINE PRODUCTION TO 705,000 UNITS
Due to increased global demand for its models with MZR engines of 1.8 or 2.3-liter displacement, Mazda Motor Corporation has plans to raise production capacity at its head office plant in Hiroshima. In May 2005, MZR engine production figures stood at 537,000 units produced per annum, and this has subsequently been raised to 650,000 units. With positive Mazda momentum creating more demand, production of the MZR engine will be further increased in January 2006 to 705,000 units per annum. Starting with the sales launch of the Mazda6 in May 2005, the MZR has become the mainstay engine of vehicles like the Mazda3, Mazda5 and MX-5 Roadster, powering roughly 75 percent of Mazda vehicles made in Japan. Additionally, in August 2005, Mazda introduced the high power and eco-friendly MZR DISI Turbo, a direct injection gasoline engine linked with an intercooler and mounted on the Mazdaspeed Mazda6. This increase in engine production capacity has become necessary to respond to the strong sales of Mazda3 and MX-5 Roadsters in Europe and North America. At the same time, Mazda is aligning its engine production and supply with a view to the U.S. launch of the CX-7 SUV Crossover, scheduled for Spring 2006, along with the Japan launch of the All-New MPV in February 2006. "Strong sales of the Mazda3 mean that Mazda has to increase production to try and meet demand and, with more new generation models coming, expanded production capacity for the MZR engine allows Mazda to respond in a flexible way," said Masaharu Yamaki, managing executive officer in charge of production and business logistics at Mazda. "The MZR engine is one of the most important powertrains in the Mazda lineup, and puts the Zoom-Zoom into many of our cars. I want to continue providing our customers with attractive cars that make them feel they have something special, something delightful, when they get a Mazda vehicle," he added. Car Reviews Concept Car Auto Insurance Tires Wheels

Ford Volunteer Corps Building a Better World
Topic: Auto News
A year ago the Ford Volunteer Corps was just an idea waiting to be put into action, but when tragedy struck December 26, 2004, the Corps quickly became a reality. Like people across the globe, Ford Motor Company Chairman and CEO Bill Ford was horrified by the destruction of the tsunami, which killed approximately 275,000 people and left hundreds of thousands homeless. The company had to do something. Bill Ford initiated the Corps to make it more convenient for employees and retirees across the globe to volunteer for projects in their communities. The first major project was working with Habitat for Humanity International to rebuild housing in areas hardest hit by the tsunami. "I am very proud of the way this company and its people responded to the tsunami crisis," said Bill Ford. "The creation of the Ford Volunteer Corps helped us institutionalize that spirit." With the help of Ford volunteers, at least two communities that were destroyed by the 2005 tsunami started to rebuild. With volunteers from Ford Thailand and Ford India taking the lead, the Corps began with the village of Khao Lak located in the Southwestern region of Thailand, and with a fishing village 100 km South of Chennai in India. Since March, Ford Motor Company has sent 25 volunteers a week to Khao Lak - these volunteers often travel as far as 14-hours away by bus from their residence in Bangkok and Rayong. To date, more than 400 volunteers have given more than 25,000 hours to this effort and will extend into the new year. In India, Ford partnered with the Confederation of Indian Industry to adopt the 255 families of Panaiyur Periya Kuppam. To date, Ford of India has donated 25 new boats and fishing nets to support 75 families, paid school fees for children, conducted a summer camp for children, organized a children's club and started an engine repair training program for youngsters in the community. "People care so deeply and want to make a difference," said Executive Director, Ford Volunteer Corps, Jim Bright. Their mission: "We work to make a living. We volunteer to make a life." Throughout the world, the Corps partners with community groups that provide volunteer opportunities to Ford employees. It is estimated that more than 100,000 employees and 100,000 retirees worldwide participate in volunteer efforts each year. Habitat for Humanity projects, part of the company's 16-hour community service program for salaried employees, is one of the most popular causes. "Employees who donated their time and talents to help tsunami and hurricane survivors tell us the experience changed their lives," said Bright. The volunteers were instrumental in providing shelter and housing for displaced families. "I can't even begin to list all of our initiatives that have helped this vital region in the Gulf Coast begin to recover," said Bill Ford. "But I can say this: of course we donated money. But at times like this, people know that Ford does more than just write a check." "Heart is something that cannot be measured, but it is something that can very much be appreciated," he added. Besides being good corporate citizens during tragedies, Ford volunteers make a difference each day in their own communities in many ways, ranging from cleaning parks and public lands to mentoring children and young adults. Volunteers throughout the world touch lives, uncover needs and bring people together. "I am reminded daily of the spirit and deep commitment of our volunteers," said Nancy McCauley-Branstetter, manager-Ford Volunteer Corps. "I hear stories every day about employees who serve their community, and who take their families on vacation overseas to build homes for people in need."
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TECHNOLOGY BREAKTHOUGHS MARKETED TO OTHER COMPANIES
Topic: Auto News
Technology such as Roll Stability Control, Night VisionTM and computer-controlled ignition keys, no doubt, make Ford Motor Company's products better. But they also have a lot of commercial value to suppliers, other industries, and even other automakers. Technology Commercialization, Inc., part of Ford Global Technologies, LLC, actively seeks markets to license out Ford's innovative technologies. By doing so it helps Ford's bottom line generating millions of dollars in license revenue and cost-savings. "We don't create the technology, but we work with Ford's technologies and think of the best commercial applications for it," said Keith Hughes, director, Technology Commercialization. "We are very much leveraging Ford's innovations." Consisting of only a five-person specialized staff, in 2004 Technology Commercialization's revenue was $4.5 million, growing by 25 percent each of the last few years. It also is projected to have earned Ford over $10 million in cost savings. Cost savings occur, for example, when a licensee takes on the cost of managing a licensed technology. Technology Commercialization manages over 200 royalty-bearing licenses, on a wide variety of technologies. Some of its top-sellers include the Ford-invented ignition keys, which they license to locksmiths and other automakers. And Ford's Night VisionTM technology-considered to be the best around-is licensed out to the government for military applications, as well as for home and commercial security surveillance. Likewise, the Ford-invented trunk release handle-which lets someone get out of a locked trunk-is licensed to DaimlerChrysler and General Motors. Software used in vehicle computer systems is another large area of Technology Commercialization's licensing efforts, generating up to 35 percent of revenues. Technology Commercialization works with automotive suppliers, such as Lear, TRW, Bosch, but they also actively seek markets in outside, specialized companies. But it isn't giving away Ford's innovative advantages, however. They are capitalizing on it. "We are generating royalty from components, but we are also maintaining a competitive advantage." said Chris Danowski, licensing manager, Technology Commercialization. "You don't necessarily want to license out your best technology, but you can offer earlier iterations, get revenue from them, and still be on top of the curve." For example, by licensing out first-generation Hill Decent Control technology, while working on second- or third-generation versions, Ford maintains its leadership. Plus, by providing earlier iterations of a technology it creates market interest in a product. Nonetheless, licensing deals with suppliers or other third parties include agreements that protect Ford's position. Technology Commercialization works closely with Ford's scientific research community, offering guidance and feedback on commercialization potential. Often scientists and engineers, so involved in the technical side, may not be entirely aware of the commercial applications. "A lot of engineers and scientists like us because they invent things or make something and it doesn't always quickly make it into production," said Hughes. "And they see us as an ally to help them commercialize their technology. So it's a real encouragement for them." With business backgrounds in sales, marketing, product development and software-the Technology Commercialization team can see things from a strategic perspective. It can work with say, Purchasing, and make sure that Ford doesn't give away its ideas, and instead looks at ways to patent and own ideas and sell them. "We are proactive about what technology we ought to be patenting and where the commercial opportunities are," said Hughes. "If, for example, there is a great technology created and Ford at the moment can't utilize it, we might go ahead and get a patent on it and try to license it out. Ford cannot use all of the inventiveness that comes out in the company, as much as I'd love that to be the case. Technologies Commercialization enables us to get good value for that kind of technology."...
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Lexus Ranks Number One in J.D. Power and Associates Customer Retention StudySM
Lexus ranked number one in the J.D. Power and Associates 2005 Customer Retention StudySM. Results released yesterday showed Lexus gaining 3.5 percentage points from 2004 to take the lead in 2005 by retaining 63.0 percent of its customers. The industry average was 49.6 percent. The study measures the percentage of new-vehicle buyers and lessees who replace a vehicle that was previously purchased new with a new vehicle from the same nameplate. According to J.D. Power, vehicle quality and customer service experiences are key factors in influencin...


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PADILLA ANNOUNCES ACCELERATION OF FORD'S INVESTMENT PLAN IN THAILAND
Ford Motor Company's President and Chief Operating Officer Jim Padilla met with Deputy Prime Minister and Minister of Industry Suriya Jungrungreangkit today and announced the acceleration of Ford's second phase of investment at its Ford/Mazda (AAT) manufacturing facility. The second phase investment will be made over three years (2005 to 2008) and underpins Thailand's importance as a major international production hub for Ford's one-tonne pickup truck. "Firstly, let me congratulate Thailand on achieving a major milest...


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Renault Trucks at BATIMAT
The International Building Exhibition BATIMAT 2005 hosted over 500,000 visitors at Porte de Versailles in Paris. The stand for Renault Trucks highlighted its special series for public works and civil engineering professionals "BTP PRO" where many contacts were established. BATIMAT 2005 is a world leader for building trade fairs,. This year the event took place on November 7 to 12 with over 2,700 exhibitors, all of which are in the building industry, over a surface area of more than 130,000 m? at the exhibition park at Portes de Vers...


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"Car of the Year 2006" in Denmark
The new Leon has been crowned "Car of the Year 2006" in Denmark. This accolade, which has been conferred by the Danish association of motoring journalists, is the first to be awarded to the new SEAT model. During their evaluation of the candidate models, the panel of 26 motoring experts paid particular attention to the following criteria: safety elements, practicality, comfort, driving characteristics and value for money. Out of the 23 cars which were entered for this award, the Spanish model came out on top ahead of the Mazda 5 an...


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"Car of the Year 2006" in Denmark
The new Leon has been crowned "Car of the Year 2006" in Denmark. This accolade, which has been conferred by the Danish association of motoring journalists, is the first to be awarded to the new SEAT model. During their evaluation of the candidate models, the panel of 26 motoring experts paid particular attention to the following criteria: safety elements, practicality, comfort, driving characteristics and value for money. Out of the 23 cars which were entered for this award, the Spanish model came out on top ahead of the Mazda 5 an...


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