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other conventional processes in mind, but to be produced with additive. "It may be that we totally change the design and geometry to get the function we need out of it but while we consolidate many parts together. We may have geometries that can't be molded that reduce weight and integrate a lot of function. "Then if you start comparing that with the cycle time or overall time to make that assembly of parts, you'll be able to start competing. And if you improve the quality overall because of this new design, you don't have to meet the short cycle time." Simply stated: A holistic view that takes into account what can be functionally realized through additive may make it more competitive when comparing that component with what is necessary to do in order to achieve the same with conventional processes. A BRIGHT OUTLOOK One of the big challenges in automo- tive is mass reduction. "If you look at what additive manufacturing is really good at, weight reduction might be something that you really zero in on." She explains that it is possible to create geometries that minimize weight without afecting performance through additive, geometries that can't be readily achieved otherwise because of process limitations. "If we concentrate on those types of applications in the short term, then there is good potential to improve quality of product. Then, as cycle times and materials improve, we will have more applications." Lee says, "I really believe that the technology is going to advance very quickly in this feld because there is so much interest in it and potential for things like customization or special geometries that are not physically possible with a mold. Those are two areas we are looking at to exploit." She adds, "Thinking about how quickly the technologies have been advancing in the last couple years, there will probably be things out in the market in fve years we can't imagine." Which is saying a lot, given the generation-long experience that Ford Motor has had with the technology. FCA US PRINTS AN AXLE HOUSING While it is important to evaluate the fow of oil inside axles and pinion carriers during development, it presents a challenge. Ordinarily, windows are cut into the components. However, during testing on dynamometers, the oil becomes milky, so not a whole lot is seen through the window. So the engineers at FCA US came up with a new approach, using additive manufacturing to print the structure with a clear material. They can run it on the dyno and still see what's going on. According to FCA US's Tom Sorovetz, the structure, which measures approxi- mately 14 x 10 x 12-in., was printed on a SLA-7000 machine from 3D Systems (3dsystems.com) using DSM SOMOS 11120 resin (dsm.com/products/somos/ en_US/home.html). The part took some 12 hours to print, then about two hours of fnishing to make the housing more clear. p To see what's going on inside an axle, the engineers at FCA US printed a clear housing. The entire thing is put on a dynamometer so that oil fow throughout the structure can be examined. AD&P; > June 2015 > FEATURE > Additive @ Ford > Gary S. Vasilash > gsv@autofeldguide.com 34