Article An Innovative Ford Sedan with Enhanced Stylistic Design Engineering (SDE) via Augmented Reality and Additive Manufacturing Leonardo Frizziero , Gian Maria Santi , Giampiero Donnici , Christian Leon-Cardenas * , Patrich Ferretti, Alfredo Liverani and Marco Neri Department of Industrial Engineering, Alma Mater Studiorum University of Bologna, 40136 Bologna, Italy; [email protected] (L.F.); [email protected] (G.M.S.); [email protected] (G.D.); [email protected] (P.F.); [email protected] (A.L.); [email protected] (M.N.) * Correspondence: [email protected] Abstract: The design of an E segment, executive, midsize sedan car was chosen to fill a gap in the market of the Ford brand and to achieve the goal of innovation looking towards the future. Ford has not owned an E-segment flagship sports sedan for years, since the historic 1960s Falcon. Starting from the latter assumption and considering that the major car manufacturers are currently investing heavily in E-segment cars, it is important to design a new model, which has been called the Eagle. This model proposed here is to fill the gap between Ford and other companies that are already producing sport cars for the electric sector and to complete Ford’s proposal. The presented methodology is based on SDE, on which many design tools are implemented, such as Quality Function Deployment (QFD), Benchmarking (BM), and Top Flop Analysis (TPA). A market analysis follows in order to Citation: Frizziero, L.; Santi, G.M.; identify the major competitors and their key characteristics considering style and technology. The Donnici, G.; Leon-Cardenas, C.; results are used to design an innovative car. Based on the most developed stylistic trends, the vehicle Ferretti, P.; Liverani, A.; Neri, M. An is first sketched and then drawn in the 2D and 3D environments for prototyping. This result leads to Innovative Ford Sedan with Enhanced Stylistic Design the possibility of 3D printing the actual model as a maquette using the Fused Deposition Modelling Engineering (SDE) via Augmented (FDM) technology and testing it in different configurations in Augmented Reality (AR). These two Reality and Additive Manufacturing. final applications unveil the possibilities of Industry 4.0 as enrichment for SDE and in general rapid Designs 2021, 5, 46. https://doi.org/ prototyping. 10.3390/designs5030046 Keywords: stylistic design engineering (SDE); car design; design engineering; QFD; benchmarking; Academic Editor: Yuping He additive manufacturing; augmented reality Received: 18 June 2021 Accepted: 22 July 2021 Published: 27 July 2021 1. Introduction Industrial design is the most important phase in the lifetime of a product. The design Publisher’s Note: MDPI stays neutral stage controls the style of the components, the costs, the times of production, and the impact with regard to jurisdictional claims in on the market. Because of the latter, it is important to gather all of the information possible published maps and institutional affil- iations. from customers and start a new project to develop the right car concept from the beginning. Errors in this phase will lead to inefficiencies that will affect the budget. Many approaches to this problem are possible since the design stage is not simple [1]. The following paper presents a case study based on the different phases of Industrial Design Structure (IDeS) with the integration of AM and AR, dividing the process into several design steps. Using Copyright: © 2021 by the authors. IDeS, it is possible to develop an innovative industrial product [2] by deconstructing the Licensee MDPI, Basel, Switzerland. process into phases concerning style, design, optimization, and production. Because of This article is an open access article this methodology, errors are reduced, and the final product result is both innovative and distributed under the terms and conditions of the Creative Commons relatively cheap since no changes need be done after the application of the methodology Attribution (CC BY) license (https:// itself. Moreover, the usage of breakthrough technologies such as Augmented Reality creativecommons.org/licenses/by/ (AR) [3] and Additive Manufacturing (AM) [4] show that non-expensive solutions for 4.0/). virtual prototyping exist, and they can be implemented in the IDeS process. As previously Designs 2021, 5, 46. https://doi.org/10.3390/designs5030046 https://www.mdpi.com/journal/designs Designs 2021, 5, x FOR PEER REVIEW 2 of 16 Designs 2021, 5, 46 2 of 17 expensive solutions for virtual prototyping exist, and they can be implemented in the IDeS reported by Donnici et al. [5], using this methodology, a link is indeed created between process. As previously reported by Donnici et al. [5], using this methodology, a link is the design structure and company organization, dividing the design process into three indeed created between the design structure and company organization, dividing the macro-phases: Setup, Development, and Production (Figure1). design process into three macro-phases: Setup, Development, and Production (Figure 1). FigureFigure 1. 1.Paper Paper architecture architecture followingfollowing IDeS ph phasesases and and implementing implementing AM AM and and AR. AR. TheThe Project Project SetUpSetUp analyzes the background background and and objectives objectives of of the the product product design. design. FirstFirst of of all,all, QualityQuality Function Deployment Deployment (QFD) (QFD) [6,7] [6,7 is] isused used to todefine define the the customer’s customer’s requestsrequests and and thethe targettarget marketmarket segment. Se Second,cond, a aBenchmarking Benchmarking an analysisalysis is performed is performed toto identify identify the the numbernumber ofof requirements that that will will allow allow the the product product to tobe be innovative. innovative. The The presentedpresented method method isis anan evolution of of the the pa pastst known known methodologies, methodologies, which which were were analyzed analyzed byby Sabatier Sabatier [[8],8], beingbeing enhanced by by a a Top-Flop Top-Flop analysis analysis to to scout scout the the number number of ofthe the main main characteristicscharacteristics ofof thethe bestbest products on on the the market, market, which which will will set set the the level level that that needs needs to be to be overcome in order to achieve innovation in the new project. Ford style was initially overcome in order to achieve innovation in the new project. Ford style was initially studied, studied, in particular of the Ford Falcon (1960–1968) and Ford Mondeo (1996–2019) in particular of the Ford Falcon (1960–1968) and Ford Mondeo (1996–2019) models, to better models, to better understand the characteristics of the brand and the main stylistic understand the characteristics of the brand and the main stylistic properties that have been properties that have been maintained over the decades. The SDE method proceeds with maintained over the decades. The SDE method proceeds with the sketching of a digital the sketching of a digital version of the vehicle here presented in order to improve the version of the vehicle here presented in order to improve the classic freehand drawing. classic freehand drawing. After finding the satisfactory shape (analyzing and discarding After finding the satisfactory shape (analyzing and discarding the various proposals of the various proposals of the stylistic trends), the proportions and dimensions of the final thesketch stylistic are trends),evaluated the and proportions corrected and through dimensions two-dimensional of the final drawings—2D sketch are evaluated CAD— and correctedbefore moving through on two-dimensionalto the second part drawings—2Dof the IDeS, Product CAD—before Development. moving on to the second part ofThis the step IDeS, begins Product with Development. the 3D modelling of the vehicle—3D CAD—to obtain the three- dimensionalThis step shape begins of withthe product. the 3D modellingOnce the 3D of model the vehicle—3D and all of CAD—toits functional obtain andthe three-dimensionalaesthetic details are shape completed, of the the product. realistic Once renderings the 3D of model the product and all are of displayed its functional before and aestheticproceeding details with are prototyping, completed, which the realistic can take renderings place physically of the product with the are creation displayed of beforethe proceedingmodel of the with vehicle prototyping, with 3D printing, which canor vi takertually place using physically Augmented with Reality thecreation to show the ofthe modelcar in ofany the real vehicle setting with of everyday 3D printing, life. orIn virtuallythe presented using paper, Augmented the authors Reality chose to showto testthe carboth in of any these real technologies setting of everyday in order life.to set In up the a presentedcomparison paper, that led the to authors a more chosecomplete to test bothstudy. of The these Product technologies Development in order phase to set ends up wi a comparisonth the optimization that led and to redesign a more completeof the study.vehicle The according Product to Development an aerodynamic phase study. ends Applied with the to optimizationthe automotive and sector, redesign the SDE of the vehiclemethod according [9,10] introduced to an aerodynamic the ability to study. digitally Applied sketch tothe the vehicle, automotive which improves sector, the the SDE methodclassic freehand [9,10] introduced drawing of the the ability vehicle. to