Auto Industry and 3D Printing
3D printing has been an important feature of the automotive development for many years. Recently, however, instances of using 3D printing have been adopted throughout the manufacturing industry; 3D printing has the potential to add significant value to the supply chain. It can open up a wide range of manufacturing and production applications. Technology is becoming increasingly profitable and affordable. Enterprises are increasingly able to use additive manufacturing within the factories to support production processes. New durable materials offer the opportunity to produce highly accurate and functional 3D parts that can replace the final part. It unlocks various options for providing customization and high-performance features, but this is only the beginning. 3D printing in the automotive industry has helped manufacturers reduce product development costs, produce lighter replacement parts, and much more.
The integration of new production methods can be daunting at first. Still, companies that have implemented 3D printing are experiencing positive effects in the production and, as a result, in the final product. In fact, businesses have increased their investment in technology and made it an integral component of their production process. The benefits are being felt in many aspects of their business. It also serves as one of the most important indicators that 3D printing is indeed the future of production.
TRANSFORMING AUTOMOTIVE PRODUCTION SECTOR
3D printing in the automotive industry has seen unprecedented development. As a production technology, it has expanded throughout the industry since its introduction. Not surprisingly, carmakers are more focused on finding new applications and advancing technology.3D printing is a groundbreaking solution for the automotive sector, a trend that is consolidating additive manufacturing across the board. Several studies are forecasting exceptional growth for additive manufacturing in the automotive industry over the next few years. Today, 3D printing technology has reached a point where it can be used by automakers to produce end-use parts. These advances are allowing for exciting new ways to design and manufacture vehicles. Above all, 3D printing technologies will play a key role in promoting competitiveness.
3D printing will have a significant impact as a source of modernization and a driving force for supply chain innovation. Automotive manufacturers implementing additive manufacturing will benefit from shorter delivery times, lower costs, and novel ergonomic designs. Overall, this highlights some of the benefits and how 3D printing can play a key role in this area of product development.
RAPID PROTOTYPING AND 3D PRINTING IN THE AUTOMOTIVE INDUSTRY
The designing stage of a new product development usually involves numerous iterations before it can be finalized. Varying with the project, it can take from a few weeks to several months. However, 3D Printing offers automotive manufacturers the opportunity to simplify and accelerate this critical phase of product design and prototype development. Among the major advantages of this technology is that it allows companies to produce variations to their products at a very low cost. By creating physical models of each new design, it is easy to view and compare the design alternatives. With the support of these prototypes, car manufacturers can enhance their products’ design in a relatively short period and at a minimal cost.
A great example is one of the world’s leading tire manufacturers. Throughout the designing stage, the company employs rapid prototyping to test various designs of the product. The final design is decided after all tactile alternatives had been tested. The appeal of this case is that it adds a valuable advantage over the competition in addition to custom prototype options for OEM customers. It provides an edge over those with limited design specifications when they share newly created products with the clients.
DIVERSE CUSTOMIZATION OPTIONS WITH 3D PRINTING
As demand for custom-built products and experiences grows, car manufacturers are more and more offering clients the options to personalize their automobiles. One of the most economical ways to achieve this customization is with 3D printing. Daihatsu, a famous Japanese car manufacturer, introduced a vehicle customization program for its vehicles in Copenhagen in 2016. Through a collaboration with Stratasys, Daihatsu customers could print individual 3D panels for the front and rear bumpers and design and order basic models in different colors. These custom parts are 3D printed in UV-resistant ASA thermoplastic filament using the Stratasys Fortus 3D printer.
The capability to create unique custom items promptly and economically makes 3D printing better than traditional methods. In Europe, BMW’s MINI brand has also been using 3D printing to produce custom automotive parts. Since 2018, MINI clients have been able to customize various trim parts such as dashboards, LED door sills, etc. The freedom to choose various colors and textures is also a huge part of this personalization experience. On top of that, the parts can be printed in 3D using a variety of technologies, from SLS to Carbon’s DLS.
3D PRINTING IN MOTORSPORTS
In Formula 1, the performance of a racing car is often the deciding factor between winning and losing. However, designing a successful racing car can be challenging, especially with the high cost and the traditional rapid prototyping cycle. Wind tunnel testing is among the key steps in developing a racing car. Car manufacturers utilize wind tunnels to test and fine-tune the aerodynamics of their racing cars. In the course of the wind tunnel testing, the vehicle model is driven on a treadmill to assess the performance of the vehicle in a simulation of the race environment.
Today, 3D printing is mostly used in motorsports to produce parts that are tested on these replica race cars. For instance, the Swiss Alfa Romeo Sauber F1 team uses a 60% scale model of the F1 car, and the majority of its parts are printed in 3D with SLA and SLS technology. Their engineers have been managed to print components such as front fenders, brake lines, engine covers, suspension, etc. faster than traditional production methods, giving them superior design flexibility.