When the new Audi E-Tron GT was launched, the Audi Sport Böllinger Höfe plant in Heilbronn, Germany, quickly needed nearly 200 new tools, jigs and tooling. Designing these tools takes a lot of time, and outsourcing production can sometimes take weeks or even months. At this time, design automation and 3D printing provide Audi Sport with an unparalleled workflow.
The Audi Sport Böllinger Höfe plant is a high-end automotive production facility. Its main production focus is the high-performance Audi R8 and the all-electric Audi E-Tron GT. These cars are top-of-the-line products from the renowned German automaker. The production line reflects German efficiency. The bare bike frame is transported via a robotic platform and secured to the upper track. These unique cars pass through multiple stations where order-specific parts are installed. It’s rare to see two identical cars, which makes the whole operation even more impressive.
Each workstation has a limited amount of time to assemble the parts and install them on the car. That’s why an optimized and efficient workflow is crucial for machinists. Customized tools, jigs and fixtures play an important role in making a machinist’s job faster, easier and more ergonomic.
“We produce nearly eight hundred tools and jigs for the factory,” said Audi Sport 3D printing expert Cem Guelaylar. “Outsourcing can take anywhere from two to three weeks, or even months, depending on the supplier and the process of getting the order to the supplier. . 3D printing helps us get these tools in a very short time. Workers come to us and say I need a jig to assemble the car.”
Different tools for different applications
There are custom tools that help align mounting components. For example, for mounting roof or exterior signs. This improves the consistency and quality of the final car while saving a few minutes per car. Quality control tools ensure all cars meet Audi’s highest standards. These custom jigs are installed on automotive components to measure alignment and tolerances. For example, Audi Sport created a custom fixture to align a head-up display (HUD) with an in-car dashboard. This fixture uses two lasers projected onto the mounted HUD. When the laser is aligned, it means the reflective glass is installed properly.
Many parts require assembly before being installed on the car. Pipes added to the central liquid plate, cables and heat sinks on the central control unit, etc. Simply placing these parts on the workbench makes the task very difficult. That’s why Audi Sport uses a lot of jigs in the factory. These clamps hold the parts in place for quick assembly. Not only do these fixtures save time, they also have a significant impact on the consistency of production. Many clamps are also designed to have a positive impact on worker ergonomics. For example, by fixing tools in a better orientation for easier work.
Design parts in minutes, not hours
So when the new E-Tron GT was launched, a big challenge was creating nearly 200 different tools, jigs and fixtures and starting production quickly. Designing these tools requires a lot of time and expertise. They need to be precise, user-friendly and easy to produce. At this time, Trinckle’s Fixturemate plays an important role. Fixturemate is a software specifically designed for creating assembly fixtures. Start by importing a part and setting it to the correct angle, then create a fixture by adding a base plate, places to support the part, and holes to secure it to the bench. The software also includes some ready-made tools, such as clamps. The software is very user-friendly and can be used by anyone. Tool design that might take hours in traditional CAD software only takes 10 to 20 minutes in Fixturemate.
“We started production of the Audi E-Tron GT all-electric car. We needed close to 200 jigs and tools. Fixturemate helped us create a large number of jigs in a short time,” Guelaylar noted. “We put the parts into Fixturemate and within minutes Just get the fixture. In traditional manufacturing, it takes us two hours or three hours.
3D printing advantages for Audi Sport
Not only does Audi Sport need to design parts quickly, it also needs to produce them in a very short time. Outsourcing production tools is expensive and can take weeks or even months. Therefore, Audi launched a 3D printing room. Multiple printers like the Ultimaker S5 enable Audi Sport to meet tooling needs. Tools can now be printed in one day at a fraction of the cost of traditional methods. No need to request quotes, brief suppliers and wait for parts to be produced and delivered. When a part does not meet requirements, it can be directly improved and reprinted.
The right material for the job
Most jigs are printed using Tough PLA. This material has flexibility and strength similar to ABS, but is very easy to print, not as difficult as ABS. There are also tools printed using TPU95a for protecting automotive parts. This soft material effectively protects components from damage.
Thanks to the UltiMaker ecosystem, Audi Sport also has access to hundreds of third-party materials. These materials often have very specific properties. One material used by Audi Sport is ESD-safe PLA for jigs that handle electronic components. Preparing these materials for 3D printing becomes very easy with Ultimaker Cura because of the free printing profiles available on the market.
“We use Tough PLA because it’s cheap and easy to use. We mainly use TPU to protect car parts. We also use ESD safe materials and sometimes ABS or PETG. For us, 3D printing is a very fast and helpful tools that serve our factories and our workers,” Guelaylar continued.
Audi Sport excels at continually improving efficiency. By starting to use 3D printing for their tools, they reduced tool production costs by more than 80% and got those tools to workers in a day instead of weeks. Furthermore, by using Fixturemate, Audi Sport has also made fixture design easy and fast. You don’t need a dedicated CAD designer to create a fixture design. From design to 3D printing, anyone can create the tools they need and start benefiting. ”
