Use case – Roush Performance (SAF)
Customer story
Roush Performance: F-150 camera mounts with SAF
USA · Automotive aftermarket · SAF / H350 · PA11
Roush Performance (founded by motorsport legend Jack Roush) develops aftermarket style and performance upgrades for vehicles such as the Ford Mustang and F-150. For a late-stage front-grill camera change on the Roush F-150, the team printed mounts with Stratasys SAF™ on the H350™ — in PA11, at volumes of several thousand production parts with PPAP-level consistency.
Source & credit: Stratasys. SEIDO Solutions is a Stratasys partner for print services and additive manufacturing support.
The challenge
An ADAS issue forced a late-stage change to the front-grill camera location. The grill was already in production; redesigning the camera mount was preferable, but new injection-mold tooling would jeopardize the production and delivery schedule (typically three to four months and about $30k).
The approach
Instead of injection molding, Roush printed the mounts with SAF on the H350. The powder-bed process delivered enough throughput over several builds for several thousand parts across the F-150 production run, with nearly isotropic mechanical properties and the consistency needed for PPAP.
Fast design iteration before production
A first 3D-printed prototype of the mount showed the design was not optimal. Roush quickly printed a better design and then the final series — without extra mold rework.
Production-ready volumes
SAF supported the full production run with thousands of parts, aligned with automotive quality requirements.
Impact
- At least ~50% cycle-time reduction vs injection molding (about eight weeks instead of three to four months)
- ~35% cost savings: about $19.5k for SAF parts vs about $30k for injection molding
- Production schedule met with thousands of mounts and PPAP-level consistency
Video
Source: stratasys.com
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