Innovations Right Out of the 3D Printer

In the heart of the Audi R8 factory in the Böllinger Höfe, there’s a futuristic hotspot: the 3D printing center in the startup/analysis center. This is where I meet Waldemar Hirsch and Cem Gülaylar, the Audi 3D printing experts. My goal for the day: with their help, I want to design and print an auxiliary tool that I will put into the hands of a production employee only hours later.

Among experts, 3D printing is known as "additive manufacturing.” Layer for layer, the 3D printer lays down the material to create new components. In contrast to traditional production methods, the material is applied bit by bit, rather than being removed as in milling, drilling, turning, or eroding. Materials such as plastic or metal are used.

It’s time to start the print-it-yourself attempt. We meet Marco, an employee from the Audi R8 assembly line. He explains his problem to us: during the subassembly of the brake calipers, a sensor needs to be screwed into place. An insertion aid that is specially designed for the sensor would make the subassembly considerably quicker and easier. No sooner said than printed! Almost, anyway. Now I’m faced with the most challenging part of the process: designing the piece to be printed in 3D.

Everything that Waldemar and Cem make is one of a kind. They custom-make each and every auxiliary tool to meet a specific need, without templates. So we first head to the Tech.Lab in the team’s creative workshop to measure the part. Thanks to their many years of experience, Waldemar and Cem know exactly what matters in the design process: precision, simplicity, and user-friendliness. On the basis of the measurements, we then draw a 3D model of the auxiliary tool in a CAD (computer-aided design) program. With its help, we go from a sketch to virtual reality in just over 20 minutes. Our one-of-a-kind plastic part begins its journey.

The 3D printer is still missing the most important piece of the puzzle: the right filament, or “plastic thread.” We decide on PLA (polylactide) plastic.  It is sturdy, inexpensive, and easy to print with, which makes it the perfect material for our assembly aid. We also choose a bright orange plastic thread, which will make it easier to find the small auxiliary tool in the assembly hall whenever it is needed. We insert the 3D printer filament and bring it up to working temperature. With delicate movements, the 220°C nozzle flies back and forth across the printing plate, building up the layers.

It seems like anything is possible — uh, printable — in Neckarsulm. By locally producing the auxiliary tools, Audi saves itself long waiting times and long-haul shipping. Aside from that, the use of these printed innovations give them more flexibility as well as the ability to act quickly and with agility — and that’s what matters in day-to-day business. 3D printing has advantages for the company, but it is especially valuable for the employees. That’s because, when all is said and done, the 3D printed tools make their work easier. My personal conclusion: Vorsprung durch 3D printing!