The impacts of robots, AI, and 3D printing are visible in greater efficiency, quality, and safety.
By Mark Shortt
When you think about all that goes into the manufacturing of a car—the complexity of the parts, the scale of production, and the rigorous quality requirements—it’s easy to see how robots have become indispensable to automotive manufacturers and suppliers in recent decades. These software-driven workhorses have proven to be so reliable, they’re taking on a widening range of manufacturing responsibilities.
Whether they’re unloading parts from machines, trimming material from parts, assembling components, or inspecting parts fresh off a CNC machine, robots can be counted on to perform repetitive tasks more accurately, consistently, and efficiently than humans. Robots can also work for longer periods of time than humans and they can improve workers’ safety by reducing exposure to hazardous conditions or materials in operations involving heavy machinery, painting, or welding.
Powersports vehicle manufacturer Massimo was planning to install an automated vehicle assembly robot line at its factory in Garland, Texas, at the time of this writing (see Automated Vehicle Assembly Line Expected to Boost Efficiency, Safety at Texas Factory). The robot line is “purpose-built to support production” of Massimo’s all-terrain vehicle (ATV) and utility terrain vehicle (UTV) lines, according to a company release. By implementing the automated line, Massimo CEO David Shan stated the company hopes to ensure that it “can continue to deliver the same uncompromising quality, reliability, durability, and performance” that its customers “have come to expect, while simultaneously adding significant efficiencies and safety advantages to the production process.”
But robots aren’t just performing more work. They’re also becoming smarter as they increasingly integrate machine learning (ML) and artificial intelligence (AI) into their capabilities. Robots driven by AI are helping to elevate production efficiencies to even higher levels while also eliminating problems caused by human error. When equipped with leading-edge sensors, cameras, and computer vision, they can catch defects unseen by the human eye, setting in motion a plan to remedy the issues.
AI drives quality, efficiency, safety
Market research firm Research and Markets recognizes the powerful impact of AI on automotive manufacturing in its new report, Global Automotive Industry Outlook and Growth Opportunities, 2024. In a release introducing the report, Research and Markets stated that generative AI is “transforming the automotive sector,” with expectations for contributing to advancements in areas like connectivity, electrification, and sustainability.
“It (generative AI) is impacting vehicle design, navigation, predictive maintenance, voice assistants, manufacturing, supply chain, and quality control, and enhancing the safety, efficiency, and personalization of in-car interactions,” the company stated in the release. “OEMs will be operating in a more challenging environment, with a focus on higher incentives and increased pricing pressure at a time when labor costs are already squeezing profit margins.”
AI meets needs for software-defined vehicles
The ascendance of software-defined vehicles (SDVs) has helped clear a path for the implementation of AI in automotive manufacturing. One upstart automotive technology company recently developed an AI-powered tool to meet the needs of automotive engineers as they work to create SDVs from idea to certification (see AI-Driven Tool Reported to Reduce Car Development Time, Costs).
According to a release from SODA.Auto, its new tool functions as a unified platform for software, electronics, and electrical architecture. It harnesses the capabilities of digital twin technologies and AI to significantly reduce the amount of time spent on each routine task. Unlike other automotive industry software tools, the platform is said to exclusively cover the entire vehicle development cycle, from idea and requirements to validation and certification.
3D printing enables complex, customized parts
Market intelligence firm GlobalData sees the implementation of 3D printing as another major advancement in today’s automotive manufacturing and supply chain sector. As it speeds prototyping and production, 3D printing reduces material waste and overall production costs, spurring efficiency and innovation, the company said.
“In the near term, 3D printing will significantly impact manufacturing methods by supporting rapid prototyping and challenging traditional approaches that rely on specialized tools and lengthy production times,” said GlobalData Automotive Project Manager Vivek Kumar, in a company release. “It also enables the development of complex components and customized parts that are often difficult to produce using traditional methods.”
A Cleveland-based company is working to help 3D printing manufacturers—including those in the automotive industry—customize products at scale without sacrificing efficiency or cost-effectiveness. Spokbee developed a platform that is said to empower manufacturers to “offer an unprecedented level of customization, with every variation designed for the specific manufacturing method and material,” according to a release from America Makes (see Product Configurator Platform Reported to Empower Mass Customization in Additive Manufacturing).
“Whether it’s custom brackets, specialized fasteners, or even complex manufacturing jigs and fixtures, our configurators empower anyone, even those without CAD expertise, to build exactly what they need with just a few clicks,” said Spokbee CEO Mac Cameron, in the release. “It’s a game-changer for industries like automotive, aerospace, and industrial manufacturing that rely on highly customized parts and tools.”
A notable example of a 3D printed part on a current automobile can be found in Ford’s 2024 Mustang Dark Horse, a street- and track-capable performance car that features advanced aerodynamics and a brawny 5.0-liter V8 engine (see Next-Generation Technologies Are Driving Efficiency in Automotive Design and Manufacturing). According to a release from Ford, the car includes a “six-speed TREMEC manual transmission that connects to the driver through a standard 3D-printed titanium shift ball.”