Ford, ExOne claims "discovery" in aluminium binder jet 3D printing for the automotive industry

The American multinational automaker, Ford Motor Company and the global leader in additive manufacturing technology providing industrial 3D printing systems and services, ExOne claimed a revolution in binder jet 3D printing for the automotive industry following a successful alliance to develop a process for the binding and sintering of 6061 aluminium parts, continuing its mission to make 2021 "the year of binder jet”.

The process is patent-pending and is said to deliver properties equivalent to that of die casting with high densities greater than 99% and is expected to “increase Ford’s efficiency” by taking advantage of the binder jet’s speed along with the part complexities, weight and part count reductions afforded by additive manufacturing. Both the organisations are all set to file collaborative and individual patents from the project.

Harold Sears, Ford technical leader for additive manufacturing said: “This is a breakthrough in making 3D printed and sintered parts for the auto industry. While the 3D-printing process is very different from stamping body panels, we understand the behaviour of aluminium better today, as well as its value in light-weighting vehicles. High-speed aluminium 3D printing paves the way for other opportunities that we’re just now starting to take a look at because of the ability to do complex parts with aluminium that previously weren’t possible. It’s opening doors for other opportunities.”

Since 2019, the project has been on course, with Ford leading from the forefront on final material and repeatability testing while a joint Ford-ExOne team has been working on specific designs for the new process. Ford has been using ExOne’s technology for some time and was an early adopter of ExOne’s sand 3D printers from the year 2000. Presently, Ford houses several ExOne systems at its Advanced Manufacturing Centre in Michigan and UK-based facility.

John Hartner, CEO, ExOne, said:  “Developing a fast, affordable, and easy way to 3D print aluminium with traditional material properties is a critical step toward light-weighting more products and delivering a more sustainable future. Our world-class engineers and scientists are focused on solving the toughest problems with 3D printing technology, and this achievement is a real win for all of us.”