Volvo Trucks North America is utilizing 3D printing technology to produce tools and fixtures used in the manufacturing process at its New River Valley (NRV) plant in Dublin, Virginia, where all trucks for the North American market are built.

The implementation of 3D–printed manufacturing tools enables quicker production and continuous quality improvements.

Adam Crowder, manager of Advanced Manufacturing Technology at NRV, is leading a global manufacturing-focused network representing 12 Volvo Trucks’ plants around the world, collaborating to develop new 3D printing applications and techniques for improved manufacturing. After years of internal exploration with 3D printing technology and fine-tuning, there are now more than 500 manufacturing tools and fixtures in use on the NRV shop floor produced using 3D printing. All of these parts were printed at the Volvo Innovative Projects lab at the Dublin facility.

Volvo Trucks North America is utilizing 3D printing technology to produce tools and fixtures used in the manufacturing process at its New River Valley (NRV) plant in Dublin, Virginia, where all trucks for the North American market are built. The implementation of 3D-printed manufacturing tools enables quicker production and continuous quality improvements. Volvo Trucks used 3D printing technology to develop a one-piece diffuser used in the paint atomizer cleaning process, saving the company more than $1,000 per part, as well as eliminating the need for a multiple piece component.

Volvo Trucks primarily uses Selective Laser Sintering (SLS), a 3D printing technology that uses a laser to sinter powdered plastic material into a solid structure that is then rigorously tested and put into use in the manufacturing process. Using SLS allows engineers to design parts by drawing the end product, putting it in the machine and leaving it to print in a matter of hours during a work day or even overnight, cutting down on the number of hours spent building parts through traditional tooling methods.

The use of this technology also increases flexibility in manufacturing, reducing the wait for new parts from vendors by simply printing them in-house. These capabilities therefore reduce inventory expenses as well, eliminating space needed to house traditionally produced tools, driving costs down in end products for customers.

Volvo Trucks used 3D printing technology to develop a one-piece diffuser used in the paint atomizer cleaning process, saving the company more than $1,000 per part, as well as eliminating the need for a multiple piece component. Spare parts were also produced for the 20 that were created so that they can easily and quickly be replaced should wear occur.

Additional examples of 3D printed parts in use at Volvo Trucks include: roof seal gauges; fuse installation platens; drilling fixtures; brake piston gauges; vacuum drill ducts; brake valve fitting gauges; hood drilling fixtures; power steering adapter holders; luggage door gap gauges; luggage door pins.