{"id":68660,"date":"2024-05-23T06:00:00","date_gmt":"2024-05-23T13:00:00","guid":{"rendered":"https:\/\/www.autodesk.com\/products\/fusion-360\/blog\/?p=68660"},"modified":"2024-05-20T00:45:11","modified_gmt":"2024-05-20T07:45:11","slug":"rivian-prototyping-process","status":"publish","type":"post","link":"https:\/\/www.autodesk.com\/products\/fusion-360\/blog\/rivian-prototyping-process\/","title":{"rendered":"Rivian Accelerates Its Prototyping Process With Autodesk Fusion\u00a0"},"content":{"rendered":"\n

You can\u2019t miss a Rivian truck<\/a> or SUV<\/a> on the road. There simply isn\u2019t anything like them. Maybe it\u2019s the glossy exterior or the oval headlights that seem to peer with a friendly look. Or perhaps it\u2019s the fact that Rivian has created an all-electric, all-terrain, \u201cadventure-ready\u201d vehicle that simply doesn\u2019t look\u2014or drive\u2014like your typical EV. They\u2019re designed for any experience, all with the goal to \u201cpreserve the natural world\u201d by offering a sustainable alternative to an internal combustion vehicle.\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

Creating an entirely new entry into the established automotive industry is no small feat. The company attributes a digital-first approach to its impressive development speed and agility. With everyone on the same page, they can learn about potential challenges before they\u2019re deep into production when it\u2019s more expensive and time-consuming to make changes. Since everything for their vehicles is designed from scratch, prototyping is a crucial component of their success. Using digital product development tools including Autodesk Fusion has enabled the team to prototype quickly, \u201cfail fast,\u201d then prototype again and again until they reach the desired outcome.\u00a0<\/p>\n\n\n

Taking the first steps with Autodesk Fusion\u00a0<\/h2>\n\n\n

Jonathan Dankenbring, product development engineering manager of the rapid prototyping group within Rivian’s Special Projects team, was the first to fold Fusion into Rivian\u2019s development process. Its simultaneous 5-axis capability initially impressed the team, but the key turning point in expanding Rivian\u2019s Fusion use was during the prototyping of the suspension for the R1<\/a>. \u201cThat\u2019s when we really realized that Fusion could do everything that we needed to create these parts,\u201d Dankenbring says.<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

Over six months, new iterations of the suspension were continuously created after testing for stress and strength. With Fusion, they could quickly modify the design of parts already made and get the new parts machined. As the suspension parts were strengthened, Rivian started testing them on the road. \u201cWe were able to fail fast and go through multiple renditions to come to the final product that you see on the vehicles today,\u201d Dankenbring says. <\/p>\n\n\n\n

\n

\u201cThe purpose of my team is to skip over all the processes that slow down a traditional car company. We want to be able to iterate as fast as possible. We want to get parts in engineers, designers, and operators\u2019 hands so that we can make our cars quickly and to quality, too. Using Fusion has allowed us to do all of that.\u201d\u00a0<\/p>\n\u2014Jonathan Dankenbring, Product Development Engineering Manager, Rivian\u00a0<\/em><\/cite><\/blockquote>\n\n\n

\u201cLong Way Up\u201d filming\u00a0<\/h2>\n\n\n

Another one of those \u201cfail fast\u201d moments occurred during the filming of the \u201cLong Way Up<\/a>\u201d television show. The series features actors Ewan McGregor and Charley Boorman traveling the globe and embarking on long-distance motorcycle rides. This time they were riding from Patagonia to Southern California on Harley Davidson electric motorcycles. The show enlisted Rivian to travel along for the filming in 2019\u2014far before the truck ever hit production. It was the ultimate test to take the early R1 model through a real-world trek of more than 13,000 miles.\u00a0\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

At one point during the filming, Dankenbring received an urgent call at 1:00 a.m. at his home in Michigan. The truck\u2019s rear suspension arm was damaged while navigating rough terrain and needed to be replaced. They\u2014quite literally\u2014couldn\u2019t hold up the show. Dankenbring said he\u2019d have the replacement part done in 8 hours. The next morning, the parts were shipped overnight across the continent to a small village in South America, installed, and they were back on the road.\u00a0<\/p>\n\n\n

Cross-team collaboration with the design studio and engineering teams\u00a0<\/h2>\n\n\n

The rapid prototyping<\/a> team receives hundreds of requests from teams across Rivian each month. In a single day it could be the design studio\u2019s request to 3D print a component, or the engineering department may need a new part machined. Communication is key to fielding and fulfilling these requests.\u00a0<\/p>\n\n\n\n

\u201cThere\u2019s a lot of collaboration working with the design studio and engineers,\u201d Dankenbring says. \u201cWe always want to try make sure it works the first time around and that it’s manufacturable.\u201d <\/p>\n\n\n\n

Matthew Yates, senior CNC machinist, helps advise on design for manufacturing (DFM) and illustrates the different problems they might encounter during the manufacturing process. For example, he recently tried to program a part, but the engineer delivered an undercut design that was difficult to machine with a standard tool.  <\/p>\n\n\n\n

\u201cI was trying all the different options for it, and finally decided to go into Fusion and split it into two pieces to see how to make it work,\u201d Yates says. \u201cI could go back and forth between CAM and CAD and use the CAD tools to split it, add some boxes, and locate features and holes.\u201d\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

Once Yates found an ideal solution, he reached out to the designer about the proposed changes. \u201cWith Fusion, I could show him on the screen that he\u2019ll end up with the same result in the end, but with two parts and a small weld. He thought it looked fantastic and asked if I needed any support from him. It wasn\u2019t necessary because we could already do it in Fusion.\u201d <\/p>\n\n\n\n

The team also benefits from Fusion having the option for parametric design or free-form modeling. Yates was recently getting some input from a welder who noted that it would be easier if the bosses were a bit bigger on the part.  <\/p>\n\n\n\n

\u201cWhen I get a design, there\u2019s no history to it,\u201d he explains. \u201cI can work with it easily in Fusion, unlike parametric-based software like SolidWorks where you need some sort of history or have to start making a history to it. To assist the welding process, I could go right into Fusion and use some of the push-pull tools just to make those holes bigger or smaller without having to worry about a history tree behind it.\u201d <\/p>\n\n\n

Moving with speed and agility\u00a0<\/h2>\n\n\n

The rapid prototyping group is a small, but mighty group of two machinists and three additive specialists with Dankenbring at the helm. They\u2019re currently laser focused on streamlining set up times and looking into automation options so they can run 24\/7.\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

\u201cWe\u2019re really focused on getting jobs set up quickly,\u201d Dankenbring says. \u201cWe aim to only do a few clicks of dragging and dropping the file into a setup environment where it automatically configures your stock size, the fixture, and the standardized tool library that looks at what material is going to be machined. We can lean on Autodesk to help us come up with better processes and get rid of all the repetitive tasks so we can click and go.\u201d\u00a0<\/p>\n\n\n\n

\n

\u201cWith Fusion, you have this ability to change a little feature on the design side and then two clicks later regenerate your toolpath on the manufacturing side to see if it helps with the toolpath. It\u2019s so quick. And it\u2019s nice being able to make those small modifications by having CAD and CAM within the same system.\u201d\u00a0<\/p>\n\u2014Jonathan Dankenbring, Product Development Engineering Manager, Rivian\u00a0<\/em><\/cite><\/blockquote>\n\n\n\n

The team also believes that 3D printing makes them better machinists. There are industrial materials on the 3D printing<\/a> side that can substitute machining many different applications. \u201cWe don’t have to tie up a machine when it’s just maybe a stand or locating pins,\u201d Dankenbring says. \u201cWe can just 3D print it.\u201d\u00a0\u00a0<\/p>\n\n\n\n

Organic shapes for custom fixtures created with generative design are becoming much more prevalent, but they can be difficult to machine. \u201cWith Fusion, we can 3D print a custom fixture overnight,\u201d Dankenbring continues. \u201cThe next day we have a finished fixture that we can throw on our CNC machine and hold an intricate part in the preferred orientation for toolpaths. That’s a game-changer right there.\u201d\u00a0<\/p>\n\n\n

Prototyping and 3D printing on Rivian\u2019s factory floor\u00a0<\/h2>\n\n\n

Dankenbring and his team aren\u2019t only prototyping for the vehicles. They\u2019re also helping to make the actual manufacturing process better, too. \u00a0
\u00a0
Even though the team is based in Plymouth, Michigan, many of their projects are created for the Rivian plant in Normal, Illinois. The plant moves incredibly fast and needs parts, jigs, and fixtures right away. To cut down the turnaround time even further, they took prototyping and 3D printing directly to the factory floor.\u00a0\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

\u201cWe were able to secure some space right in the middle of the plant, and we currently have about 14 additive machines down there right now,\u201d Dankenbring says. \u201cIt\u2019s run by one of our teammates, and he uses Fusion to help with the design for additive manufacturing and alter any models to make them more printable. He can provide that same day or next-day delivery of urgent jigs and fixtures that they want to use on the line to make the operator’s lives easier and just make cars go down the line faster.\u201d\u00a0<\/p>\n\n\n\n

When the rapid prototyping team receives a request for a jig or fixture from the process engineers at the plant, they first look at the complexity and reach out to the requester to ensure they fully understand the application. With that context, they can make more strategic decisions on the design, material, and production methods. <\/p>\n\n\n\n

\u201cWe\u2019re all driven by the fact that we want to make it fast and without much cost,\u201d Dankenbring says. \u201cJust 10 or 15 minutes of design work in Fusion makes the manufacturing of these parts so much quicker. The requesters are excited about the fact that they don’t have to wait an extra week for their jig to get there.\u201d <\/p>\n\n\n\n

This tag-team effort of design, 3D printing, and machining was especially successful to create new efficiencies for the production of inverters that sit on top of the drive units. During the process of putting an inverter together, it goes down the conveyor belt to robots that add and screw in components. However, the station continually dropped screws into the inverter. Not an ideal situation when the line would be held up to retrieve them.\u00a0\u00a0<\/p>\n\n\n\n

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Image courtesy of Rivian.<\/em><\/figcaption><\/figure>\n\n\n\n

A process engineer came to the team to see about creating a lid to go on the inverter as it went down the line. That way the screws would land in the cover\u2014not the inverter. The team took the design, dropped it in Fusion, and split up all the different components for both 3D printing at the factory and machining in Michigan. <\/p>\n\n\n\n

\u201cOriginally, the engineer just wanted it all machined,\u201d Dankenbring says. \u201cBut we offered 3D printing portions of it to cut down time and cost. By combining all these different technologies within our team, we could crank out all the laser-cut parts within a few hours, machine pins on our 5-axis lathe, and 3D print hundreds of inserts on our powder bed fusion printer, the Stratasys H350.\u201d <\/p>\n\n\n\n

The first version was tested and required some tweaking. The team pivoted and updated the design in Fusion. Within a week, the team completed 100 covers at a cost of only $20 each. The best part? There was zero disruption on the line in that area moving forward.<\/p>\n\n\n

Looking to the future\u00a0<\/h2>\n\n\n

The entire team is always on a mission to keep innovating and providing new, better ways to work. With Fusion, they can stay one step ahead. \u201cOver the past five years, Fusion has grown right along with us,\u201d Dankenbring says. \u201cIt seems like every couple of months we have a new feature in Fusion that makes our jobs a little bit easier\u201d\u00a0\u00a0<\/p>\n\n\n\n

A driving force for the entire team is the fact that their work is going towards Rivian\u2019s mission to create an impactful product that helps make the world more sustainable. Every day is a new adventure. <\/p>\n\n\n\n

\u201cWe have talented engineers and designers that challenge us each day to bring their prototypes to life,\u201d Dankenbring says. \u201cThere’s always something new, whether it\u2019s a prototype gadget from our Adventure Products<\/a> group, or shiny new suspension arms from the Chassis team. We work with great software and great people here at Rivian. It\u2019s exciting all the time, and I\u2019m lucky to work with our incredible team.\u201d\u00a0<\/p>\n","protected":false},"excerpt":{"rendered":"

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