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Roush/Google Cars


Challenge

Roush turned to Barron Industries for help in filling Google’s order for 100 driverless cars in a record nine months, concept- to-completion. Barron shared our expertise in rapid prototyping, large high strength thin wall aluminum investment castings, and in-house CNC machining to provide a turnkey solution for many of the spaceframe and suspension components.

Solution

The “node” castings for the tubular spaceframe were cast as one piece versus an original multi-piece tubular fabrication. The construction holes for the adhesive that bonded the entire frame were cast in to size and location. The steering knuckles, control arms, shock supports and transmission cradle castings were provided completely machined including the press fitting of all bushings and bearings ready for final assembly.

Results

Barron concurrently produced rapid prototype patterns and finished castings for the first 25 vehicles that were delivered a mere eight weeks after receipt of the contract and 3D math data while building hard tooling for the remaining 75 vehicle sets. Thanks to the close working relationship between Barron and Roush engineers, they met their compressed timing deadline and successfully launched the first driverless cars in North America.