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Nissan European Technology Center
(NETC)
 Solid Imaging Enables "Test By Design"
Process at Nissan
The Challenge
At the Nissan European Technology Center (NETC), engineers have created a series of "test by design" functions, which dramatically reduce the need
for real-life test work. As a result, NETC is recognizing significant cost savings in tooling
production, in addition to reducing design to manufacture lead times.
In order to facilitate this process, NETC has turned to 3D Systems’ solid imaging
technologies. The ThermoJet® solid object printer is installed in the CAD section of the Design Group, at its
technology center in England, where it plays a key role in this test-by-design philosophy. The printer is used throughout the design process to produce rapid
3-D models of various vehicle components — from engine parts to interior fixtures — providing
product development teams with both an effective visual and tactile method of reviewing
designs.
3-D Printing Provides Valuable Feedback
3-D printing technology is proving extremely useful for testing design issues relating to
space management, which is essential to all aspects of vehicle design and build. The engineers simply
produce a life-size solid model of the required component and take it to the vehicle to test for fit.
The Design Group at NETC encompasses approximately 350 professionally qualified design
engineers, working on all aspects of European vehicle design and build, from lifecycle management
of existing models to the development of brand new vehicles. The CAD department, under
the management of Ian Turner, is an integral part of the Design Group, providing a key support
role through the use of the latest technology.
"The installation of the ThermoJet printer is helping to create savings in the design and development
cycle, by enabling us to capture design changes earlier in the process than we previously
could," explains Turner. NETC operates a CAD package that is complemented by the I-DEAS®
Master Series to handle their solid modeling functions.
It is from this facility that files are downloaded to the ThermoJet printer, which uses an approach
similar to ink jet printing; however, the jets in the printhead dispense a plastic-like material to
create the solid model.
"By providing a 3D solid object which they can handle and review, virtual reality becomes real, and understanding is greatly
enhanced."
Ian Turner, Nissan European Tech.Center
Benefits of "Physical" Reality
As part of the digital process, NETC has also installed an advanced virtual reality suite for
viewing product designs, from single components to sub-assemblies and even complete vehicles.
Even though this suite is at the forefront of design visualization technology, the design
teams involved still cannot actually touch the item being viewed. 3-D printing technology enables fast, accurate and cost effective solid models to be produced,
which can be brought to these sessions to complement the virtual reality experience, enabling team members to pick up
and handle the components.
Turner explains, "This is particularly useful, as the design teams often incorporate
members from other areas of the organization, such as marketing, who may not understand the engineering complexities of the product they are viewing.
Although virtual reality enables excellent design visualization, it is still not true reality. By providing them with a 3-D solid
object which they can handle and review, virtual reality becomes real, and understanding is greatly enhanced."
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