General Motors uses AM polymer composite tools for lightweight assembly lines

General Motors lightweights assembly lines with AM polymer composite tools

Summary

Challenge icon

Challenge

  • Automotive assembly line
  • Riser for overhead conveyor needing replacing once per month
  • HEAVY – 34kg – steel and aluminum holder slowing the pallet movements
  • SLOW to deliver – 13 weeks – or repair
  • COMPLEX manufacturing combining conventional metal forming, welding and manual assembly
  • COSTLY – due to metal subtractive manufacturing
Solution icon

Solution

  • Nylon 12 Carbon Filled large parts
  • Single composite additive part replacing unnecessary multi-part metal assembly
Value icon

Value

  • 74% tool cost saving
  • 56% weigh saving reduces conveyor’s energy consumption
  • 75% lead time reduction, from 13 weeks to 3 weeks
  • Inhouse repairs in days vs waiting weeks for delivery from OEM
  • No in-house labor needed for welding, metal forming, assembly
Products & Services icon

Products & Services

Stratasys F450mc or F900 with Nylon 12 Carbon Filled material

Case Provided by: Stratasys logo insight Contact for more details here.
AM I Navigator Maturity Model
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AM is considered o support strategic goals and implemented in selected application families. Dedicated team is set-up to oversee projects and allocate resources effectively.

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Initial consideration of AM. Basic use of DfAM and rudimentary part adjustment. Basic validation and approaches towards standards.

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Sourcing of materials meeting internal standards. The selection of materials is now based on functional requirements of the application.

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Beginning to evaluate AM technology and understand its implications. Focus on the printing process and use of standard properties and processes.

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Cost / weight / lead time saving for existing assembly flow
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Professional MOM as a standalone system. Mainly manual creation of BOM & BOP per build job. Integrated non-conformance, standardized defect declaration, and certification. No integration between ERP and MOM systems.

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Product and Process quality planned and inspected for manufacturing process compliant with industry standards.

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Maintenance & Service as needed, and event triggered.

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Implemented resource efficiency measures; basic recycling and minimal energy reduction efforts; initial lifecycle assessments.

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Competence development becomes more targeted with specialized training in specific dimensions of AM.

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