“Manufacturing Innovation” employs a combination of technology and storytelling that emotionally moves the audience. This permanent brand destination not only provides an immediate “Big Wow,” it was designed and built to stand up to heavy use, day-in and day-out, over many years. It included unprecedented challenges such as reprogramming two industrial robots into showpieces, something for which they had not been designed, and filming dangerous manufacturing processes. To serve The Henry Ford’s mission, the experience celebrates human ingenuity and inspires tomorrow’s innovators.

Additional innovations created or utilized specifically for this experience include:

1. 3D modeling, 2” scale models for projection tests, and the latest video mapping servers to trouble-shoot programming and installation issues.

2. Developed code to enable entertainment show systems to interface with industrial robotics.

3. Utilized state-of-the-art fog distribution system.

4. Partnered with three lighting firms to design a 100% LED lighting system and puck light enclosure that allows for over 60 LED RGBW individually-controlled floor lights.

5. Installed self-reporting system with over 65,000 possible error codes that communicates with consulting technical teams around the U.S. and enables onsite technicians to problem solve, check equipment, and focus lighting from any touch screen in the facility.

6. Special effects that increase the show’s immersive quality include: full 360° spherical video, captured and projected on screens covering the circumference of the theater and used simultaneously for reflections on the truck; 360° panoramic stop motion time lapse footage; convincing, full-range projection effects that create realistic images of the truck from all audience angles; synchronization of the robots with the animation on the surrounding screens and the floor to create fully immersive effects throughout the theater; combined laser effects and rendered projections that create the illusion the truck is being 3D printed during the model’s reveal.

Early results indicate “Manufacturing Innovation” is meeting all objectives. Proof points include:

• FRFT ticket sales were up 16% in January 2015. Truck sales were up 17% calculated over the same two months. There were over 120 media visits to the FRFT during January as well.

• Visitor feedback has been incredibly positive and has reflected audiences are getting the message about Ford’s leadership role toward a better future for transportation, and more importantly, for the planet.

• School group visits in January 2015 increased at least 17%. Teachers are applauding the experience’s presentation of STEAM (Science, Technology, Engineering, Arts, and Math) in a real-world application, inspiring visitors (especially students) and emphasizing 21st Century design, engineering, and manufacturing skills. An education specialist at The Henry Ford stated: “We had a group of students from a school for the deaf visit today. They loved the “Manufacturing Innovation” Theater. They sat absolutely rapt throughout the show, gasped a few times during the show, and at the end they jumped up and cheered! One of the teachers thanked us for having a show that her students could feel and fully experience.”