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Ford engineers in Europe have come up with a novel and revolutionary way of designing anti-theft locking wheel nuts using 3D printing technology. Together with EOS, a leading provider for high-end solutions in additive manufacturing, Ford has created locking nuts with contours based on the drivers voice.

Like an iris scan or a fingerprint, a persons voice can be used as a special biometric identification. Engineers record the drivers voice for a minimal of one second, saying something like I drive a Ford Mustang, and use software to convert that singular sound wave into a physical, printable pattern. This pattern is then became into a circle and used as the design for the locking nuts indentation and key.

With the geometry in place, the nut and key are designed as one piece, then 3D-printed using acid and corrosion resistant stainless steel. When finished, the nut and key are separated, with a small quantity of grinding required to make them ready for use.

The design also consists of second stage security aspects that prevent the nut from being cloned or copied. The unevenly spaced ribs inside the nut and indentations that widen the deeper they go prevent a thief from making a wax imprint of the pattern, as the wax breaks when it is pulled from the nut.

If not using the drivers voice to create the contours, the nuts could feature designs specific to a vehicle, such as with the Mustang logo, or use the drivers initials. The layout ought to also take concept from a drivers interest, for example, through using the outline of a famous racetrack.

Expanding the use of 3D printing

3D printing, or additive manufacturing, provides design flexibility to assist minimize weight, enhance performance and create parts that wouldnt be possible using traditional methods. For more than 30 years, Ford has increasingly used 3D printing to make prototype parts which assist minimize the development time for new vehicles.

The company has also used this technology to create parts that feature in the Ford GT, Focus and Mustang GT500, and will make more 3D-printed parts in the future. Special bespoke car parts are also 3D printed, which includes the consumption manifold in Ken Blocks Hoonitruck and the pair of wind louvres found on the M-Sport Ford Fiesta World Rally Championship car.

On the Ford production line, 3D printing is used to create assembly line equipment that are up to 50 per cent lighter, which makes repetitive tasks much less bodily stressful and helps improve manufacturing quality. As many of these tools are made of nylon, Ford has added a recycling programme that turns old 3D-printed pieces and plastics from manufacturing areas into one hundred per cent recycled nylon. Ford also creates 3D-printed security equipment, such as safety sleeves for rotating tools used on the production line, which prevent operators from incurring finger and arm injuries.

Quotes

Its one of the worst experiences for a driver, to find their car up on blocks with all 4 wheels gone. Some alloy wheels can value thousands to replace, but these special rim nuts will stop thieves in their tracks. Making wheels more secure and providing more product personalisation are further proof that 3D printing is a game-changer for car production.
Raphael Koch, research engineer, Advanced Materials and Processes, Ford of Europe.

Having our very own plug-and-play printer allows us to make equipment and parts exactly when we want them, and to substitute them faster than ever before. For some tools, the shipping time was up to eight weeks, but with 3D printing, the turn-around has been reduced to just 5 days. Best of all, anyone can sit down, create the part they want and begin printing it using recycled plastic.
Lars Bognar, research engineer, Advanced Materials and Processes, Ford of Europe.

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