How is 3D printing being used to change the way cars are made? Can automakers utilize this process to make entire cars yet?
You won’t be able to buy a fully 3D-printed car at the dealership, but this process of creating various parts is being used more widely in the automotive industry. One vehicle that took advantage of the process is the Ford Maverick truck with its FITS system, which is a system of creating various in-cabin storage solutions via 3D printing processes.
Let’s take a look at a few ways 3D printing is transforming car manufacturing.
Same-Day Prototypes
Ford has created a Rapid Technology Center in Merkenich, Germany, which can produce some interesting prototypes. Instead of waiting several weeks to see a physical prototype, engineers ca use 3D printing to create the physical prototype out of their designs in a matter of hours. These same-day prototypes make it much easier to quickly make changes and alterations, shortening the time between concept and production produces. This process helps designers continue to develop parts tat can improve vehicle performance and longevity through innovation.
Lighter Parts
Plastics and composite materials can be lightweight solutions that make vehicles lighter. Typically, these materials are utilized for interior items that won’t be put under heavy duress. The team at IGESTEK in Spain specializes in the development of lightweight solutions using these materials and 3D printing. They also use this process to manufacture rapid tooling, making it much easier for automakers to get the job done. Using these materials can allow some parts to be up to 40% lighter than the original parts, which can make a huge difference in performance cars.
Molds and Dies
Molds and dies are how car parts are stamped out of metal, but some parts aren’t made of metal and still require special molds and dies for stamping. Makra Pro has developed a process for molding leather using 3D-printed dies. They can shape and emboss real leather using molds printed on Form 3, which is the technique the company uses. It expands foam to equally distribute pressure across a panel of stretched leather, allowing the material to take on the shape pressed into the die.
Manufacturing Aids
It’s not economical or logical to build the tooling for every part to test it and ensure it will work. Instead of creating massive tools and machines for this purpose, Dorman Products creates manufacturing aids that can help automakers develop new parts for cars that might not come out for a couple of years. Using 3D printers, this team develops the text fixtures and gauges and completed the prototyping of the product to create the final design that must be tested as well.
Aftermarket Pars
Some vehicles are rare or require special parts that might only be requested a handful of times. Older model vehicles often don’t have the same aftermarket parts support as modern vehicles, which means finding original parts can be difficult. Whether it’s parts for an older car or something that can be produced through 3D printing, BTI Gauges can support the needs of the aftermarket automotive sector. The aftermarket shortage can be filled with parts that are processed this way and function, as well as OEM parts that might be difficult or impossible to find.
Performance Parts Production
We aren’t at a point in time when an engine can be produced using a 3D printer, but some performance parts found in the engine bay can be produced this way. Forge Motorsport makes aftermarket parts for performance cars using 3D printing processes. When Toyota came out with the GR Yaris the team at Forge found ways to improve the inlet duct design, which improved the overall performance of this performance car. This makes for an exciting use of this process to create improved performance and driving fun.
Carbon Fiber Molding
Similar to the molds and dies for leather and interior materials, 3D printing can be used to create the molds used for carbon fiber parts. Using these molds, the team at Formula Student, a yearling engineering and design competition, has much greater flexibility in what they can create. This molding process also allows greater flexibility, shorter lead times, and saves costs while designing key parts for vehicles. Machining some parts would require expensive specialized materials and greater lead times, but this team can do it much faster using a 3D printer.
The use of 3D printing is becoming an extremely important part of automotive manufacturing and development, allowing automakers and suppliers to develop parts and prototypes faster than ever before.