By 3D printing their tools, jigs, and fixtures, Volkswagen Autoeuropa slashed cycle time operation, reduced labor, and minimized material wastage. Tool ergonomics have been improved, there’s less need for reworking, and best of all, it’s all achieved at a tenth of the cost. 

The company is on track to save €150,000 by the end of 2017.

Before using Ultimaker’s 3D printers, Volkswagen Autoeuropa outsourced their custom tool manufacturing. This meant waiting for several weeks, especially when multiple designs or assemblies were required.

It also meant more paperwork, a haphazard ‘trial-and-error’ approach, plus more quotations – holding up the process at significant extra cost.

Key benefits

Complete customization

Greater design flexibility means that even complex concepts can become a reality. Function and performance now drive your ideas, not cost or time.

Faster production

With their Ultimaker 3D printers, Volkswagen Autoeuropa’s tool development time is reduced by 95%. Solutions are tested without using 3rd party suppliers, and production times are cut by 8 weeks on average.

Unlimited revisions

It’s easy to verify function and design by 3D printing the part, then make new iterations within a few hours – with no cost penalties.

Reduced costs

You can test prototypes instead of redesigning, or altering an existing mold. Volkswagen Autoeuropa achieved a 91% cost reduction with their 3D printers.

Improved ergonomics

Ultimaker’s 3D printers give you the flexibility needed for continuous improvement – ensuring the best possible ergonomics and quality. 3D-printed tools are visually pleasing, lightweight, and machinable.

Better workflow

By using the 3D printers, shop floor operators become involved in the process and can offer invaluable input. Positioning 3D printers by the assembly line means operators can verify/review – swiftly and easily.

Cost Analysis

Wheel protection

Used during the position and screw assembly to prevent scratches /damage to the wheels. Without this protection, scrap costs can be huge.

Poka-Yoke
External suppliersUltimaker 3D printers
Cost€800/part€21/part
Project56 days10 days

Triangular window gauge

Achieves the best accuracy for rear quarter window positioning, ensuring a consistent finish.

Gauges
External suppliersUltimaker 3D printers
Cost€180/part€35/part
Project8 days6 days

Liftgate badge

Badges

Ensures the correct positioning of the 2.0 TDI emblem.

External suppliersUltimaker 3D printers
Cost€400/part€10/part
Project35 days4 days

Ultimaker 3: Technical Specifications

Ultimaker 3Ultimaker 3 Extended
Printer and printing properties
TechnologyFused Deposition Modeling (FDM)Fused Deposition Modeling (FDM)
Print headDual extrusion print head with a unique auto-nozzle lifting system and swappable print coresDual extrusion print head with a unique auto-nozzle lifting system and swappable print cores
Build volumeLeft nozzle: 215 x 215 x 200 mmRight nozzle: 215 x 215 x 200 mmDual material: 197 x 215 x 200 mmLeft nozzle: 215 x 215 x 300 mmRight nozzle: 215 x 215 x 300 mmDual material: 197 x 215 x 200 mm
Filament diameter2.85 mm2.85 mm
Layer resolution0.40 mm nozzle: 200 – 20 micron0.80 mm nozzle: 600 – 20 micron0.40 mm nozzle: 200 – 20 micron0.80 mm nozzle: 600 – 20 micron
XYZ accuracy12.5, 12.5, 2.5 micron12.5, 12.5, 2.5 micron
Print head travel speed30 – 300 mm/s30 – 300 mm/s
Build speed0.40 mm nozzle: up to 16 mm³/s0.80 mm nozzle: up to 24 mm³/s0.40 mm nozzle: up to 16 mm³/s0.80 mm nozzle: up to 24 mm³/s
Build plateHeated glass build plateHeated glass build plate
Build plate temperature20 – 100 °C20 – 100 °C
Build plate levelingActive levelingActive leveling
Supported materialsNylon, PLA, ABS, CPE, CPE+, PC, TPU 95A, PP, PVANylon, PLA, ABS, CPE, CPE+, PC, TPU 95A, PP, PVA
Nozzle diameter0.40 mm, 0.80 mm0.40 mm, 0.80 mm
Nozzle temperature180 – 280 °C180 – 280 °C
Nozzle heat up time< 2 min< 2 min
Build plate heat up time< 4 min (20 -> 60 °C)< 4 min (20 -> 60 °C)
Operating sound50 dBA50 dBA
Material recognitionMaterial recognition with NFC scannerMaterial recognition with NFC scanner
ConnectivityWi-Fi, LAN, USB portWi-Fi, LAN, USB port
MonitoringLive cameraLive camera
Physical dimensions
Dimensions342 x 380 x 389 mm342 x 380 x 489 mm
Dimensions (with bowden tube and spool holder)342 x 505 x 588 mm342 x 505 x 688 mm
Net weight10.6 kg11.3 kg
Shipping weight15.5 kg16.8 kg
Shipping box dimensions390 x 400 x 565 mm390 x 400 x 680 mm
Power requirements
Input100 – 240V 4A, 50-60Hz 221 W max.100 – 240V 4A, 50-60Hz 221 W max.
Output24 V DC, 9.2 A24 V DC, 9.2 A
Ambient conditions
Operating ambient temperature15 – 32 °C, 10 – 90% RH non condensing.
See material specifications for optimal conditions.
15 – 32 °C, 10 – 90% RH non condensing.
See material specifications for optimal conditions.
Nonoperating temperature0 – 32 °C0 – 32 °C
Software
Supplied softwareCura, our free print preparation softwareCura, our free print preparation software
Supported OSmacOS, Windows and LinuxmacOS, Windows and Linux
Supported filesSTL, OBJ and 3MFG and GCODEBMP, GIF, JPG, and PNGSTL, OBJ and 3MFG and GCODEBMP, GIF, JPG, and PNG

3D-Printed Assembly Portfolio by Volkswagen Autoeuropa