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Ford Motor Company

Ford Research Laboratory ensures quality control and reduces Inspection Costs with ShapeGrabber®

About the company

Ford Motor Company is an American multinational automobile manufacturer headquartered in Dearborn, Michigan. Founded by Henry Ford and incorporated on June 16, 1903, the company sells automobiles and commercial vehicles under the Ford brand, and luxury cars under its Lincoln brand.

Joseph A. Szuba

Principal Research Scientist Associate Manufacturing Systems Department Ford Research Laboratory Ford Motor Company

The Challenge

"The Ford Research Laboratory needed to make 3D measurements of complex tool shapes."

The Ford Research Laboratory was developing a new tooling production process using Spray Metal Deposition. This process would reduce production time and offer cost savings over traditional tooling methodologies while maintaining performance characteristics.

In developing the Spray Metal Deposition process, the Ford Research Laboratory needed to make 3D measurements of complex tool shapes used at three distinct milestones in the process:

  • Completion of the initial tooling
  • Completion of the ceramic
  • Completion of the tool

The OGP Solution

Using the ShapeGrabber Ai810 Automatic 3D Laser Scanning System, the Ford Research Laboratory was able to ensure that the initial tooling model, the ceramic die, and the final tool were within process specifications. ShapeGrabber’s laser scanner systems scanned components at each milestone and compared the scan data with CAD drawings using Innovmetric’s PolyWorks|Inspector™ software (available with ShapeGrabber).

A ShapeGrabber Ai820 3D laser scanning system by OGP

The Results

"ShapeGrabber’s laser scanner systems scanned components at each milestone and compared the scan data with CAD drawing."

Using color maps generated by the ShapeGrabber scans, the Ford Research Laboratory was able to identify areas in which dimensional differences occurred between components, and use that information to take corrective action.