A booming technology that increases savings and sustainability

Additive manufacturing, or 3D printing, has gained momentum and notoriety in recent years thanks to its ability to streamline production, reduce costs and allow greater customisation in the manufacture of components and complete vehicles; revolutionising the way vehicles are made. 

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Article published in AutoRevista 2.402

One of the most notable advantages of additive manufacturing technology in the automotive industry lies in the ability to customise. Automotive manufacturers can create customised parts and components to meet the specific needs of their customers. This not only allows for greater flexibility in design and production, but also results in increased efficiency and customer satisfaction.

It also allows greater freedom in component design, leading to optimised efficiency and weight reduction. Lighter vehicles consume less fuel and deliver better performance. Ford or Volkswagen Group, among other manufacturers, have adopted this technology to create lighter and stronger structures, leading to more efficient and sustainable vehicles.

Another advantage is the ability to create prototypes quickly. Designers and manufacturers can print components and evaluate their functionality in a matter of hours rather than weeks, speeding up the process of developing new models.

Additive manufacturing is undoubtedly contributing significantly to cost reductions in vehicle manufacturing, eliminating the need for expensive tooling and reducing material waste. In addition, on-demand production reduces the need to hold large inventories, which can save money on warehousing and inventory management.

Other opportunities that arise with 3D printing relate to the recycling of materials. Defective or old components can be shredded and reused in the printing of new parts, further reducing waste and reducing environmental impact.

Thus, we can highlight that the four most common applications of 3D printing in the automotive sector are: prototyping; manufacturing of tools, jigs and fixtures; production of maintenance and repair parts and spares.

Challenges and the future 

Despite the obvious benefits, the widespread implementation of 3D printing in automotive is not without its challenges. The technology has yet to overcome hurdles related to the quality and durability of printed parts, as well as regulation and safety certification.

As automotive 3D printing continues to advance, we are likely to see further integration of this technology into vehicle production, including the printing of critical components.

Improvements in the size of industrial printers, the speed at which they print, and greater flexibility in design and materials are all contributing to 3D printing in the automotive sector becoming a more viable mainstream manufacturing method. This is especially true for low to medium volume production runs of high-value, geometrically complex components.

Green mobility

The automotive sector, like all others, is under pressure to become more sustainable. One clear advantage that 3D printing offers is the use of lighter parts to reduce the overall weight of a vehicle and therefore reduce fuel consumption. A guide value is that a 10% weight reduction generates a 6% improvement in fuel efficiency. In the case of electric vehicles, the improvements in fuel consumption can be even greater. A 10% weight saving in an electric vehicle can increase range by up to 14%.

3D printed automotive parts also eliminate the carbon emissions inherent in global supply chains. In addition, 3D printers generate far less material waste during the manufacturing process compared to machining, where up to 98% of a metal block can be removed.

All international car manufacturers have introduced or will soon introduce some form of electric vehicle, from family saloons and futuristic concepts to SUVs and supercars. Industry and consumer interest is accelerating as many countries and cities have declared that they will ban the sale of fossil-fuelled cars.

As a result, new applications for 3D printing in the automotive sector are continually emerging. Some of the areas that are expected to experience substantial growth in the coming years are: green mobility, electric vehicles, and 3D printed cars.

Lightweight 3D printed automotive parts can help offset the added weight of batteries and reduce the overall weight of the vehicle. This helps to increase the maximum possible range and extend battery life.

3D printed cars

Fully 3D printed cars on public roads may happen sooner than we think, according to some experts. Several companies are taking the concept seriously. California-based Divergent, for example, aims to revolutionise automotive manufacturing with its 3D printed nodes connected by carbon fibre tubes. The result is an industrial-strength chassis that can be assembled in minutes. Its engineering prototype, Blade, has been described as "the world's first 3D printed supercar". By using lightweight materials to create strong and efficient complex structures, Divergent aims to reduce the tooling, cost and time associated with traditional car manufacturing, while increasing sustainability and innovation.

Stellantis has already established a partnership with Turin-based Competence Industry Manufacturing 4.0 (CIM4.0), which aims to accelerate the development of additive manufacturing in the automotive sector. CIM4.0's competences and technologies will be integrated with those of Stellantis to enhance the additive manufacturing capabilities at Stellantis' engineering centre in Mirafiori.

In the focus of the industrial sector

This technology is holding its inaugural event on 3 and 4 June 2025 in Bad Nauheim (Germany). This first meeting will bring together a specialised network of engineers, researchers and industry experts focused on advancing additive manufacturing (AM) for the automotive sector.

This event will be dedicated exclusively to exploring how the automotive industry can harness its potential while overcoming the challenges posed by just-in-time (JIT) production models. Attendees will explore the latest developments in: rapid prototyping, optimisation of specific functions, on-demand component creation, crucial to reduce costs and increase efficiency.

As the automotive industry looks for ways to incorporate AM without compromising production capabilities and lead times, this conference will offer valuable insights, case studies and strategic discussions on how AM technologies fit into the rigorous standards of automotive manufacturing.