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3D printing is redefining how we create countless things — one layer at a time. With extensive use in the medical and aerospace industry, we’ve seen 3D printing advance prosthetics and rocket science alike. However, the use of additive manufacturing in the automotive industry has grown substantially over recent years. Research firm Skyquestt valued the global automotive additive manufacturing market at $2.05 billion in 2022 and expects it to grow to $11.26 billion by 2030.
How 3D Printing is Used in the Automotive Industry
3D printing, also known as additive manufacturing, has revolutionized various industries by offering innovative solutions to age-old problems. In the automotive sector, it's proving exceptionally valuable for rapid prototyping, tooling, and maintenance, repair, and operations (MRO). See an overview of current use cases below.
Rapid Prototyping
Accelerated Development: Car designers and engineers can create physical prototypes of parts or even entire vehicle models in a fraction of the time required by traditional methods.
Cost Reduction: Significantly lower costs for producing prototype parts compared to conventional manufacturing techniques.
Design Flexibility: Enables quick iterations and testing of multiple design variants for components like engine parts, interior elements, or aerodynamic features.
Complex Geometries: Allows for the creation of intricate designs that may be challenging or impossible with traditional manufacturing, such as optimized cooling channels in engine components.
Tooling
Custom Assembly Tools: Rapid production of specialized jigs and fixtures for vehicle assembly lines, improving efficiency and ergonomics.
Injection Mold Prototypes: Creation of prototype molds for testing before committing to expensive production molds, particularly useful for interior trim pieces or small exterior components.
Composite Tooling: Manufacture of layup and trim tools for producing carbon fiber or other composite parts used in high-performance or lightweight vehicles.
Ergonomic Hand Tools: Design and production of customized tools for assembly line workers, reducing fatigue and improving productivity.
Maintenance, Repair, and Operations (MRO)
On-Demand Spare Parts: Printing replacement parts as needed, reducing inventory costs and vehicle downtime. This is particularly valuable for vintage or limited-production vehicles where traditional spare parts may be scarce.
Legacy Part Production: Manufacturing discontinued parts for older vehicle models, supporting the classic car market, and extending the lifespan of vehicles.
Customized Repair Solutions: Creating tailored repair parts or tools for specific vehicle models or unique damage scenarios.
Localized Production: Enabling dealerships or service centers to produce certain parts on-site, reducing shipping times and costs.
How Additive Manufacturing Is Already Making a Difference
It's worth noting that 3D printing has been used in the automotive sector for years. About a decade ago, Volkswagen became one of the first car companies in the world to use it for prototypes.
Today, Ford, Toyota, Chevrolet, Kia, Hyundai, Fiat Chrysler, and BMW are all leveraging 3D printing technology in various aspects of their operations. Even luxury automakers like Bugatti use 3D printing too. In 2018, the brand unveiled 3D printed titanium brake calipers weighing just 6.4 lbs. That's nearly half the 10.8 lbs of their traditional aluminum counterparts.
In automotive design, shaving off even a few ounces is a game-changer for performance and fuel efficiency. But weight reduction is just the tip of the iceberg. 3D printing allows for the creation of complex geometries that would be impossible or prohibitively expensive with traditional manufacturing methods. This opens new possibilities for optimizing part designs, improving aerodynamics, and enhancing overall vehicle performance.
3D printing is also making waves in the realm of customization. While building a car with unique features is traditionally a costly and time-consuming process, 3D printing makes it possible for car manufacturers to offer a wider range of personalization options without significantly increasing production costs or time. Individual printers can complete unique parts as quickly and efficiently as they can standard ones. It's simply a matter of having the right software and workflow in place.
The Investments and Returns at Stake for Car Manufacturers
A key ingredient of success with additive manufacturing in automobile production is setup. Companies need to invest in robust 3D printing systems capable of working with a variety of materials, from plastics to metals. Equally important is the development of a digital library of part designs; quick access and efficient modification will streamline the production process. Software integration is important, too. CAD programs need to seamlessly interface with 3D printers while minimizing the need for manual intervention.
Companies with robust additive manufacturing infrastructure are better positioned to both innovate and pivot in response to market changes or supply chain disruptions. This flexibility could prove invaluable in an industry increasingly shaped by rapid technological advancements and shifting consumer preferences.
The environmental impact of 3D printing in automotive manufacturing is also worth noting. By enabling more efficient use of materials and reducing waste, additive manufacturing decreases the carbon footprint associated with traditional manufacturing processes and transportation of parts.
The Forward Momentum of 3D Printing on Full Display
The adoption of 3D printing in the automotive industry represents a fundamental shift in how cars are designed, developed, and manufactured. Challenges remain in terms of material properties, production speed, and quality control. But these hurdles will and are gradually being overcome as this technology matures. Within the next decade, we can expect more surprises and innovations from automakers leveraging this technology. From fully 3D-printed concept cars to mass-produced vehicles with numerous 3D-printed components, the possibilities are expanding rapidly.
The Czinger 21C highlights the potential of 3D printing not just in prototyping, but in actual production. This 2.8-liter V-8-powered beast is the first street-legal hyper car of its kind. The father-and-son team of Kevin and Lukas Czinger designed and fabricated many components using 3D printing technology.
The 21C's performance speaks for itself while offering a glimpse into what a future of widespread use might look like. At the Circuit of the Americas, it set an official lap time of 2:10.7. The 21C also shattered the production car hill climb record at the Goodwood Festival of Speed, clocking in at 48.82 seconds on the 1.16-mile run. This feat unseated the previous record holder, Rimac's Nevera, by a significant margin.
These massive performance gains symbolize the power of 3D printing in the automotive sector. As additive manufacturing continues to evolve, it offers new possibilities for innovation, efficiency, and sustainability in car production.