Modern Examples of 3D printing in the Car industry

Modern Examples of 3D printing in the Car industry

Supply chain disruptions in recent times have impacted the Automotive industry heavily. With an increase demand for new vehicles, it is more evident that something new needs to be introduced to help alleviate the pain. 3D printing can be considered as the solution. Here are some real use cases for additive manufacturing in the industry, and even cases where production parts are being printed to produce incredible looking features.


Porsche Custom Seats

Initially as a concept, the German brand has introduced a lattice design for their sports seats. Polyurethane central seat and back rest cushions are customised to an owner’s comfort needs with 3D printed technology. Drivers can choose hard, medium, or soft setups and each seat is custom made to produce a snug fit for the driver in the motorsport environment.


Porsche Custom Seats


Ford Mustang Shelby GT500

Back in 1988, Ford were the pioneers in the 3D printing space, having bought just the third ever 3D printer. They now have an additive manufacturing facility worth over $45 million. Its new Mustang GT500 is the most advanced Mustang from an aerodynamics point of view to date. Real use cases include over 500 designs for cooling and aerodynamics were studied for achieving Fords demanding downforce, braking, and cooling goals. With this, the Engineering team were able to print 10 designs of front splitter wickers to improve downforce, testing all at once on various vehicles.


3D Printed Cars

Something as large as a passenger vehicle cannot possibly be 3D printed right? Think again. Local Motors in Arizona are one of many companies trying out the possibility of this. 2014 saw the first ever 3D printed car, named Strati, revealed at the international Manufacturing Technology Show, and entirely made from 3D printed parts. The company has some of the largest 3D printers in its facilities, with the Strati taking a total 44 hours to complete. Its wheels and hubcaps were produced using a direct metal printing process. The larger roof and lower body of the vehicle utilised ORNL’s Big Area Additive Manufacturing (BAAM) and Thermwood’s Large Scale Additive Manufacturing (LSAM) machines.

Large 3D Printed piece

Lamborghini Parts

Remarkably, in 2020, the Italian supercar brand produced 20,000 final parts using 3D printing. Using EPX 82 material, redesigned parts were produced to form lightweight alternatives. Examples include a textured fuel cap and air duct clips in their latest SUV, the Urus.


Small 3D printed part

It does not end here - the Huracan incorporates 3D printed brackets to hold important carbon fibre pieces in place, as well as a one-off key to open the bonnet. Lamborghini plans to increase their production of printed parts and evaluate if it is beneficial as a business case in their future low volume models.

Custom Lug Nuts

Ford are at the forefront again with 3D printed custom locking wheel lug nuts to reduce car theft in European markets. The increased complexity of these printed nuts means that they are difficult to copy. It uses a sound wave pattern to create a completely unique design and level of security, which can be compared to fingerprint identification.


Modern examples of 3D Printing in the car industry Written by Alex Bull

Automotive Writer, Engineer and overall enthusiast.

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