Smart Molding International 3-2021

additive manufacturing 18 smart_molding international 3/2021 Dynamic implementation of 3D printed tools, jigs and fixtures in assembly lines E veryone everywhere has heard of Nissan. There’s no denying that Nissan has made a name for itself as a giant in the automo - tive industry – together with Alliance Partners Renault and Mitsubishi, they sell 1 in 10 cars worldwide! Since its creation in 1933, the com - pany has always put an emphasis on innovation, and this constant incorpo - ration of new technologies has led it to 3D printing. The team in the Barcelona factory has chosen to use a small farm of BCN3D printers to create various tools, jigs, and fixtures. The constant evolution of the Nissan factory in Barcelona constantly keeps the workers on their toes. The team is often challenged to manufacture new parts, and subsequently come up with innovative and versatile techniques to account for it. “Every year we’re printing a total amount of approximately 100 jigs and tools with a specific use in our processes.” – Carlos Rellán Martínez, Manager of Maintenance & Engineer - ing Facilities at Nissan Motor Ibérica Zona Franca, Barcelona. Prior to printing Before 3D printing changed the game, Nissan outsourced all of its prototypes and specific jigs for minor change trials to mechanical suppliers using tradition - al manufacturing methods. This meant that two vital aspects of running a production line were being lost: time and money. Moreover, in their outsourcing they experienced is - sues of unreliability, and a strict sched - ule meant that they were limited in terms of flexibility. To put it plainly, the entire process from designing, refining to printing would take a week with an external supplier; with the use of in-house 3D printing, the team found the lead time could be reduced to just one day. In terms of costs, the price of us - ing methods such as CNC and drilling Automotive giant Nissan is relying on a small farm of BCN3D printers in its Barcelona factory to fabricate 700 tools, jigs, and fixtures in its car assembly lines so far. Trim & Chassis Manufacturing Kaizen Engineer Enric Ridao and Manager of Maintenance & Engineering Facilities Carlos Rellán gave an insight on their immense savings in time and costs: reducing one week to one day, and costs to 20 times less.