Ford Pro’s clever 3D-printed tool helps make Transit even more reliable

Most drivers change gears dozens of times during a single journey, but for working Transit vans, especially those making deliveries, that can soon multiply.

Ford Pro is always looking to help maximise uptime for its customers. Now, we have come up with a clever way of ensuring the largest van from Ford Pro – Europe’s leading commercial vehicle brand for the past eight years – ¹ is even more reliable.

Transit gearboxes are equipped with a synchroniser sleeve, a part that helps ensure smooth and reliable gear changes. During production, this sleeve undergoes a hardening process, using an induction tool, during which temperatures reach as high as 820°C.

Our engineers designed and developed a special 3D-printed copper induction tool that better distributes heat to help deliver a more robust part. Furthermore, the use of 3D printing to produce the tool eliminates waste, while powering the process with solar energy reduces emissions.

“This was a unique challenge because copper is not typically used in the 3D-printing process but the team was determined to find a way to make it work. We could see a clear benefit to our customers that will make a real difference to their businesses and to their day-to-day drives.”

Stefan Zimmermann,

Ford manufacturing and plant engineering manager

Ford Pro first started using this innovative tool to help produce our Transit vans last year – and the team’s ingenuity has been recognised at the 2023 Henry Ford Technology Award for manufacturing.

The next step? We are now exploring using the tool to play an even bigger role in future, to help create the next wave of electric vehicles.

¹ Austria, Belgium, Britain, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Netherlands, Norway, Poland, Portugal, Spain, Romania, Sweden, Switzerland, Türkiye.

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