Manufacturing the Ford Mustang Triangle Window Calibration Fixture with Low Cost and High Efficiency by 3D Printing

In 1903, Henry Ford founded the Ford Motor Company, which is headquartered in Dearborn, Michigan, and is now a world-famous automobile manufacturer. The Mustang series has been in production since 1964, making it Ford's oldest model.

CHALLENGES

The fixture used to accurately locate and install the Mustang's triangular window had several problems that needed improvement.

High cost
Making such tools requires a time-consuming process of CNC machining and welding
Low efficiency
The current tool design limits the line of sight and increases the difficulty of installation, and the external pneumatic piping also increases the space taken up by the fixture.
Heavy

The whole metal fixture has air lines and positioning devices, so it is very heavy, un-ergonomics and difficult to use.

Using FDM technology to manufacture the new fixture

Trigger type double control switch, improve ergonomics.
Existing positioning fixture details, mounting brackets and pneumatic controls can continue to be used.
Integrated pneumatic tube positioner and optimized pneumatic valve and switch bracket.
Ergonomic handle.
Increasing the density of the material where strength is needed and decrease the density where it is not needed.

RESULT

After the first design iteration, Ford realized that additional improvements were needed. Details on the window hanger are obscured by the upper bar of the frame, and there is an offset in the lateral direction when the main vacuum sucker is activated. To address these issues, the upper rail was moved up and the detail bracket was redesigned to provide a better view during production.
An inner ribbed tube was added to increase frame strength and lateral stiffness without changing the external shape. The jig is made from Stratasys Nylon12 Carbon Fiber material, which also reduces weight without compromising strength and stiffness. The 3D-printed calibration fixture is reduced to less than 5kg when fully assembled, reducing the operator's burden.
The 3D printing technology allows Ford to iterate and test designs, as well as make additional changes quickly. Additive manufacturing is cheaper and faster than using CNC machining techniques.

The above is quoted from Stratasys

As Stratasys's Platinum Partner in Asia Pacific with a large-scale 3D printing service base, 3DPlink has a number of industrial-grade printing equipment, such as F900, Fortus 450mc, Fortus 380mc. We have rich experience in printing fixtures and jigs, and provide global customers with the highest precision and strength tools. The following cases are shared: