ArcelorMittal Tubular Products in London, ON has a strong history of supplying high quality axle assemblies to various OEM platforms for both high and low volume programs.  Their value-add solutions and strong design engagement differentiate AMTP from their competitors and contribute significant EBITDA to the group.

In the current environment, creative solutions are sometimes required even for the most conventional applications. Typically, AMTP works with the customer on the product definition and supplies the prototype assemblies for launch testing.  This ensures the product requirements are tailored to the manufacturing capability and heads off any potential design concerns early in the program.  It also allows for an ample supply of parts availability to prove out new equipment.  

The Ford Warthog program is far from typical.  AMTP was awarded the program late in the launch after prototype had been supplied by a competitor.  AMTP will supply their first parts directly in the OEM product validations (PV) builds, while also managing a compressed build timing due to the late kickoff.   It is a daunting task, but also an opportunity for innovation to shine. 

CAD is great asset for designing the product but in many cases, a physical part can speak volumes.  The right-hand 23 kg axle assembly is large: 800mm long with 7 brackets, a flange and a tube all welded together.  The left-hand part shorter, but of similar complexity.  We reached out to the customer to get some prototype parts, but they were in short supply.   What are the options when you have no access to parts?  You get creative.

steel part

We started to wonder if 3D printing would be a viable option.  Due to the size and complexity, we were concerned that the overall cost would be prohibitive, but it warranted more investigation. AM Dofasco Hamilton has a small 3D printer, so the search started there.  Brian Nelson advised that Mohawk college had larger printing systems and there was potential to leverage an existing contract.  We “met” virtually with the Mohawk team to banter the pros and cons of different manufacturing methods and moved forward with Fused Deposition Modeling (FDM) technology of the individual components.  These were glued together to make the assemblies. 

Within two weeks, we had completed printed components which cost only a few hundred dollars.  The collaboration was a win-win for all sides.  We got the parts for our use while the students gained practice with an actual industrial application.  It was so successful we printed an extra set of the brackets. 

We have found numerous uses for the 3D printed parts.  Due to the weight of the plastic parts, they can be easily viewed from all angles which is challenging with a 23 kg welded steel assembly.  Numerous times they have been used in explaining some feature of the part or the manufacturing process whether it be the assembly welding or the machining or sub-component manufacturing processes.  The printed brackets were used for the initial fit-up trials for the bracket weld fixtures.  To prepare for the assembly CMM measurement, the first draft of the CMM program was set up using the 3D printed part.  The program will need a bit of refinement once the steel assembly is ready, but it is a good start.  It was also useful in the preliminary finished good (FG) packaging trials.  A well-designed FG tray will nest the part securely in transport to prevent damage.  It also serves as part orientation for loading and unloading.