The Nuclear Powered Car From Ford

July 8, 2021 by Al Williams 42 Comments

We think of electric cars as a new invention, but even Thomas Edison had one. It isn’t so much that the idea is new, but the practical realization for normal consumer vehicles is pretty recent. Even in 1958, Ford wanted an electric car. But not just a regular electric car. The Ford Nucleon would carry a small nuclear reactor and get 5,000 miles without a fillup.

Of course, the car was never actually built. Making a reactor small and safe enough to power a passenger car is something we can’t do even today. The real problem, according to experts, is not building a reactor small enough but in dealing with all the heat produced.

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Ford And HP Teamed Up To Drive Down Plastic Waste

April 3, 2021 by Kristina Panos 25 Comments

This mass manufacturer movement towards electric cars is one thing, but what about sustainability on the plastic part production line? Ford and HP have teamed up to turn used 3D printed parts and powders into pellets that will be fodder for injection-molded parts — specifically the fuel-line clips for Super Duty F250 trucks.

According to Ford’s press release, their goal is to reach 100% sustainable materials in all their vehicles, not just the diesel-drinking Super Duty. Their research team found ten other Fords whose existing fuel-line clips could instead be made sustainably, and the company plans to implement the recycled plastic clips on all future models.

There are all sorts of positives at play here: the recycled clips cost 10% less to make and end up weighing 7% less than traditionally-made clips, all the while managing to be more chemical and moisture resistant.

And so much plastic will be kept out of landfills, especially once this idea takes off and more manufacturers get involved with HP or form other partnerships. One of the sources of Ford’s plastic is Smile Direct Club, which has 60 printers cranking out over 40,000 dental aligners every day.

There’s more than one way to combine 3D printing and sustainability. Did someone say fungal sound absorbers?

[Images via Ford]

Pandemic Chip Shortages Are Shutting Down Automotive Production

January 18, 2021 by Lewin Day 66 Comments

Once upon a time, the automobile was a mostly mechanical beast, but no longer. Advanced electronics have weaved their way into the modern car, from engine to infotainment and climate control to the buttons now sprinkled throughout the passenger cabin. The gains in amenity and efficiency can’t be sniffed at, but it leaves manufacturers reliant on semiconductor suppliers to get cars out the door. Over the past year, it’s become much more complicated — with many automakers having to slow production in the face of integrated circuit shortages that can be traced back to Spring of 2020. Continue reading “Pandemic Chip Shortages Are Shutting Down Automotive Production” →

Ford’s Powershift Debacle

June 3, 2020 by Lewin Day 203 Comments

In the automotive world, change is a constant, and if you’re not keeping up, you’re falling behind. New technologies and methodologies are key to gaining an edge in the market, and companies invest billions each year trying to find the next big thing, or even the next minor incremental improvement.

In just such a quest, Ford Motor Company decided to explore an alternative to the traditional automatic gearbox, aiming for greater fuel efficiency in their small cars. On paper, there were gains to be had. Unfortunately, not everything went according to plan. Continue reading “Ford’s Powershift Debacle” →

What Happens To Tesla When The Sleeping Auto Giants Awake?

August 12, 2019 by Jenny List 158 Comments

The history of automotive production is littered with the fallen badges of car companies that shone brightly but fell by the wayside in the face of competition from the industry’s giants. Whether you pine for an AMC, a Studebaker, or a Saab, it’s a Ford or a Honda you’ll be driving in 2019.

In the world of electric cars it has been a slightly different story. Though the big names have dipped a toe in the water they have been usurped by a genuinely disruptive contender. If you drive an electric car in 2019 it won’t be that Ford or Honda, it could be a Nissan, but by far the dominant name in EV right now is Tesla.

Motor vehicles are standing at the brink of a generational shift from internal combustion to electric drive. Will Tesla become the giant it hopes, or will history repeat itself?

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Ford Ka Becomes Diwheel Monster

October 24, 2018 by Lewin Day 27 Comments

If you’ve been to the right events, you’ve seen them before – the cars with an external cage that let the car complete a somersault in the forward direction under heavy braking. They’re impressive, but it’s possible to take things even further. Enter [mastermilo82] and the RollKa.

The RollKa follows on from the RollGolf, which was a straightforward roll car build. Built around a Ford Ka, it eschews the external cage for a more radical design. The Ka has been shortened, and designed to fit within two enormous steel rims which wrap around each side of the car. Additional idler wheels have been welded to the Ka’s roof to enable it to effectively roll within the outer steel rims.

It’s a rather eccentric design, known as a diwheel. We’ve seen impressive electric versions before, but at least at this stage, this project appears to lack any advanced control systems and gets by on sheer luck and welding prowess. The build is still at an early stage, with episode three starting some early movement tests under power. It’s a testament to what can be achieved with a spacious garage and some imagination, and we can’t wait to see what happens next! Video after the break.

[Thanks to Baldpower for the tip!]

Continue reading “Ford Ka Becomes Diwheel Monster” →

Printed Part Gets Classic Truck Rolling

August 8, 2018 by Tom Nardi 19 Comments

When working on classic vehicles, and especially when modifying them outside of their stock configurations, things can get expensive. It’s a basic principle in economics: the rarer something is the more money somebody can charge you for it. But if you’ve got the skills and the necessary equipment, you can occasionally save yourself money by custom-fabricating some parts yourself.

After changing the gear ratio in his 1971 Ford F100, [smpstech] needed to adjust his speedometer to compensate. Unfortunately, a commercial speedometer reducer and the new cables to get it hooked up to his dash would have run into the hundreds of dollars, so he decided to try designing and 3D printing his own gearbox. The resulting development process and final product are a perfect example of how even a cheap desktop 3D printer, in the hands of a capable operator, can do a lot more than print out little toy boats.

The gearbox contains a large ring gear driven by a smaller, offset, spur gear. This compact inline package drops the speed of the input shaft by 25.5%, which [smpstech] mentions is actually a bit slower than necessary, but it does give him some wiggle room if he decides to change his tire size.

Even if you’re not looking for a speedometer reducer for a nearly 50 year old truck, there are some lessons to be learned here in regards to 3D printed car parts. The first version of his gearbox, while functional initially, ended up looking like a deflated balloon after being exposed to the temperatures inside the F100’s engine bay. His cheapo PLA filament, which is probably fine for the aforementioned toy boats, simply wasn’t the right material for the job.

[smpstech] then reprinted the gadget in HTPLA, which needs to be annealed after printing to reach full strength. Usually this would involve a low-temperature bake in the oven, but he found that simmering the parts in a pot of water on the stove gave him better control over the temperature. Not only did the HTPLA version handle the under-hood conditions better, it was also strong enough that he was able to use a standard die on the connections for the speedometer cables to create the threads instead of having to model and print them. Definitely a material to keep an eye on if regular PLA isn’t cutting it for you.

This isn’t the first time we’ve seen 3D printed parts used to get a vintage vehicle back on the road. Building these custom parts would have been possible without a 3D printer, of course, but it’s a good example of how the technology can make these types of repairs faster and easier.

[via /r/functionalprint]