Cutting-Edge Technology and World-Class Manufacturing Factory to Produce Electric Vehicle (EV) Battery Enclosures

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Foundry Corporate News

24. September 2024

DURA Automotive Systems is a global automotive supplier headquartered in Auburn Hills, Michigan, specializing in the design, engineering, and manufacturing of solutions that drive the evolution of mobility. With a legacy comprising more than 100 years of inspired invention, the company is recognized by leading vehicle manufacturers as the preferred supplier partner for innovative, highly integrated, mechatronic driver control systems, lightweight structural body systems, and a portfolio of precision-manufactured automotive products

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Ultramodern Manufacturing Facility

The world-class Muscle Shoals factory supplies lightweight EV battery enclosures to the Alabama-based Mercedes-Benz electric battery pack plant in Bibb County. The new state-of-the-art manufacturing facility is DURA’s latest investment in vehicle electrification. Previously, DURA launched an advanced lightweight EV structural systems plant in the Czech Republic and opened its second site to manufacture EV battery enclosures in the Republic of North Macedonia.

Imperial Quality and Reliability

The most recent addition to a growing family of worldwide sites is home to cutting-edge manufacturing processes that utilize advanced robotics and proprietary forming and joining technologies to produce lightweight structures for EV battery systems.

These structural enclosures, often integral to the vehicle’s chassis, safeguard the EV battery modules and their supporting electrical and thermal management systems. They are made of lightweight material to minimize energy consumption and extend vehicle range and recharge intervals.

Consequently, the structures must be precisely manufactured and accurately inspected to ensure they meet the highest quality and reliability standards and contribute to EVs’ overall efficiency, safety, and performance.

Capacity and Flexibility Issues with the CMM

DURA has been using a coordinate measuring machine (CMM) to perform its quality controls – and for good reason. CMMs are the most accurate metrology equipment for quality inspection. However, relying on only one stationary CMM, the metrology department struggled with capacity and flexibility issues. The CMM was often extremely busy with all types of inspection, and the EV battery enclosures had to be brought to the metrology lab for measuring.

DURA started looking for additional inspection capability to meet their need for flexibility and mobility, crucial for supporting their growing operations. The company wanted to ensure it sought out the most advanced technology for its precise measurement requirements.

Trust in the MetraSCAN 3D|BLACK Elite and HandyPROBE

In its quest for new, innovative technology to meet its measurement needs, DURA opted for the Creaform optical CMM MetraSCAN 3D|BLACK Elite and portable CMM HandyPROBE, paired with Polyworks. “Creaform and Polyworks have a strong reputation in the 3D measurement industry,” says Branden Head, Metrology Supervisor at DURA. “Our sister facility in Europe had previous experience with Creaform, and the positive feedback weighed heavily on our decision.”

High Accuracy Captured on the Shop Floor

The fast and accurate 3D scanner and portable CMM have been engineered to perform highly accurate and repeatable metrology-grade measurements and 3D geometrical surface inspections directly on the shop floor. Equipped with their MetraSCAN 3D or HandyPROBE, the metrology department could capture characteristics at 0.025mm (0.0009 in) accuracy without moving the structures to the metrology lab.

This move from touch probing to 3D scanning also enabled DURA to acquire a larger quantity of data quickly, compared to only a few discrete points collected slowly with CMM. In addition, the whole battery enclosure can now be measured in a single setup since the entire part fits into the system’s field of view, eliminating leapfrogs and reducing the measurement time.

Used as a mobile measurement station whenever needed, the metrology-grade 3D scanner and portable CMM added intermediate checks directly on the production floor, influencing the overall quality and efficiency of the manufacturing process. Now, more EV battery enclosures can be inspected in less time. In parallel, Creaform’s measuring solutions helped reduce the workload of the traditional CMM, assigning it to critical inspections with tight tolerances.

Helpful Training and Fantastic Support

DURA initially received a one-week training course to learn how to operate the 3D scanners and software to their full potential. An additional follow-up training was also offered to improve their measurement results. The engineers described the training as very beneficial and easy to understand.

Creaform’s application engineers and technical support were available whenever DURA reached out for questions. Their answers were informative and helpful. “We rely on internal and external resources to ensure that our team fully utilizes the equipment to best serve our facility,” says Mr. Head. “Creaform’s ongoing support has been integral to our growing team.”

Pivotal Increase of Measurement Capability

We use the Creaform MetraSCAN 3D and HandyPROBE as portable measurement stations to measure incoming extrusions and get quick scans of the product before it moves forward to a mill to ensure the mill will accept the part. Thanks to Creaform, we have increased our capacity by 75%. -Branden Head, Metrology Supervisor at DURA Automotive

The distinct performance obtained with Creaform and Polyworks in DURA’s production environment has confirmed their strong reputation in the 3D measurement industry. “Creaform and its 3D measurement solutions were pivotal for the measurement capability in our facility,” adds Mr. Head. “Our project would have struggled with capacity and mobility without Creaform’s and Polyworks’s technology.”

The partnership between DURA and Creaform will certainly continue as the global automotive supplier is now exploring the possibility of integrating Creaform technology into its automated manufacturing process. For sure, the metrology team can always count on Creaform’s dedicated training and support to achieve this next goal.