Ford streamlines design process with latest 3D technologies

Ford has released details of its use of new digital technologies in streamlining its design process.

Designers use what they call the 3D CAVE – Computer Automated Virtual Environment – to recreate a car's interior by projecting images onto the large white walls and roof. 3D polarizing glasses framed with motion sensors are used to transport them into the car's virtual interior. Ford currently uses two CAVE systems – one in Cologne, Germany, and the other in Dearborn, USA – while other single wall systems are used at other studios.

The aim is to streamline the design process and make it easier to implement changes to the smallest interior detailing, while the CAVE can also create an animated external environment, complete with pedestrians and cyclists to help designers check for maximum visibility from inside the car.

Virtual reality supervisor at Ford of Europe Michael Wolf says, "We can now conjure up a car in the digital world and then actually get in and experience it.

"We still rely on the know-how and imagination of our prototype engineers to bring designs accurately to life, but now they have at their disposal a much more sophisticated tool to do so."

The CAVE is credited with the development of the Ford B-Max's Easy Access Door System, which uses hinged front doors and sliding rear doors integrated into the central body pillars to give passengers maximum ease of access. The 3D simulations of different windscreen wiper systems also let designers spot the most efficient for the B-Max – the 'butterfly' system, where the wipers move in opposing directions.

Ford also used the CAVE during the Focus' design process to enhance windscreen wiper effectiveness, maximize room for rear passengers, evaluate door frame design impact on visibility and minimize reflections.

"The CAVE makes it so much quicker and easier to analyze designs," says Wolf. "For example, to manufacture three different front pillar design examples and fit them to a prototype vehicle could take 10 days. The same project could be completed in just one or two days using our virtual reality simulator – and also saves physical resources."

When the CAVE can't be used, designers use 3D printing to build shapes from thousands of layers on top of each other. This method was used for a door handle and seat panels for the B-Max and front pillar trim and tailgate bump stops for the new Kuga. Ford is also examining the possibility of expanding the use of the process in future model development.

Sandro Piroddi, supervisor, Rapid Technology at Ford of Europe says, "3D printing means we can create all kinds of complex shapes and one-off components that would previously have required many man-hours and resources to produce manually or through machining. It has huge potential for Ford vehicle production in the future."

By Rufus Thompson