Expanding Applications and Utilizing Materials: Toyota Industries Corporation's 3D Printer Utilization Strategy

At the R&D Administration Center of Toyota Industries Corporation in Japan, the company’s approach to selecting the materials and methods for manufacturing on what’s optimal for a given application, rather than simply using a machine because it was introduced. This approach is underpinned by a corporate culture that encourages competition even within the group and a philosophy that the frontline staff should actually choose the equipment they use.

Toyota Industries Corporation evolved from its original business of loom manufacturing to handling various R&D projects and manufacturing critical components like compressors. A key tool for their Additive Manufacturing Group are 3D printers. We interviewed Hiroyuki Oiwa, Group Manager of the Technical Management Department, R&D Administration Center, Toyota Industries Corporation, who is responsible for promoting additive manufacturing at the company, about the history of 3D printer utilization and the manufacturing methods he is focusing on.

According to Group Manager Oiwa, the Toyota Group is not a monolithic organization based on a division of labor; fundamentally, each company is independent. If similar parts exist, the group companies compete with each other, and when similar parts are manufactured, a final decision on adoption for Toyota vehicles is made after a competition. 

Toyota Industries Corporation is involved in a wide range of fields. In the automotive sector, it manufactures vehicles like the RAV4, engines, compressors for car air conditioners, DC-DC converters, on-board batteries, and charging-related inverters (a product that converts the in-car voltage to 100 V, allowing household outlets to be used for things like camping). However, even these products are subject to competition for each vehicle model. Outside of automobiles, the company handles industrial vehicles, including forklifts, and textile machinery.

Group Manager Oiwa joined the R&D Administration Center in 2019. His predecessor had been solely using an inkjet 3D printer for prototyping. Inkjet 3D printing allowed for large-scale models in color, and the quality of prototypes was good. However, looking toward the future with the aim of moving to promoting AM company-wide, including for end-use parts, Oiwa realized that this method would be difficult for manufacturing end-use products.

Group Manager Oiwa and the executive in charge of the manufacturing department surveyed people who were independently using fused deposition modeling (FDM) 3D printing in their respective departments and established the "3D Printer Liaison Group" with these individuals as members. In October 2019, they began company-wide 3D printer utilization promotion activities, extending beyond prototyping.

As a result of investigating 3D printers actually used for mass production worldwide, two methods were found promising: stereolithography (SLA) and selective laser sintering (SLS). For SLA, they purchased a Formlabs Form 3 3D printer and another printer simultaneously, allowing the frontline staff to test both and make a selection.

Different departments used the available 3D printers, with each user choosing the material and printer for a specific job. Departments also shared the features and benefits of different printers. Gathering together the responses and which printers where used most, a printer was gradually selected: Form 3.

Group Manager Oiwa unequivocally states material as the reason for the printer selection. While the industrial material they had hoped to use for the other printer was discontinued shortly after its introduction, Form 3 was compatible with many materials and could meet a variety of needs. 

When Form 4, the blazing fast next-generation SLA 3D printer was introduced, Toyota Industries Corporation, adopted it with support from Harada Vehicle Design, responding to workplace needs.

The philosophy of workplace choice is also well-reflected in the process of adopting Fuse Series SLS 3D printers. Although Group Manager Oiwa was initially recommended Fuse Series printers by Ito of Harada Vehicle Design, he hesitated to adopt it immediately due to concerns about powder residue and surface roughness. Internally, people accustomed to injection-molded products also worried abut surface roughness. 

The turning point was hearing a lecture by Shinya Takei of Owl Craft Co., Ltd. at a Formlabs user meeting. Learning that Owl Craft was actually manufacturing and selling products using Fuse Series 3D printers, convinced Oiwa that SLS could be used for end-use part production. Furthermore, the introduction of the Fuse Blast for automated post-processing made it clear that the issues of powder residue and surface quality could be significantly resolved. He saw the physical product and decided on the adoption there and then.

Following the introduction of Fuse Series 3D printers, the scope of requests expanded significantly. Consultations began coming from departments that had not made requests before, including not just technical divisions, but also the environmental team, public relations, and design personnel.

A specific example cited was a component for motor evaluation. Complex shapes, such as those requiring coil winding and testing, are difficult with FDM, and while SLA can manufacture them, the mechanical properties required can be best achieved with SLS materials. 

Another significant advantage of SLS is the lack of supports, enabling complex geometries that would be difficult to produce using other 3D printing technologies. This plus the high level of precision has led to positive evaluations and repeat orders for parts printed on Fuse Series printers. 

To mark the company’s one hundredth anniversary in January, a light fixture modeled after the shuttle of an automatic loom was also created for the lobby of the new headquarters — and printed with a Fuse Series printer. The part needed to be lightweight so that it could hang, as well as heat resistant. Given these conditions, Nylon 12 Powder (PA12), was judged to be the most suitable.

While the breakdown of requests fluctuates depending on the time of year, jigs account for about 30%, and prototypes 60%. Among the prototypes, 40% are for functional evaluation and 20% for fit and form.

The ultimate goal Group Manager Oiwa envisions is mass production. 

The medium-term plan for owned equipment includes the introduction of large-format powder bed fusion machines, like the Jet Fusion. However, the current strategy is to first acclimate with technology like the smaller Fuse series 3D printers, become proficient in their use, and then expand. 

Group Manager Oiwa states that while AM has made significant progress, the mass production is the final hurdle. There is still a way to go before reaching a level usable in Japan's manufacturing sites. Nevertheless, he expresses a desire to progress each year.