An increasing number of automobile producers are adopting 3D printing to enhance their manufacturing processes and provide extra personalised automobiles. Whether or not for electrical vehicles, mass-market fashions, or luxurious vehicles, 3D applied sciences are a part of the worth chain, and have turn out to be one instrument amongst many different conventional processes. Certainly, in 2023, the worldwide automotive 3D printing market reached $4.7 billion, with forecast progress of 14.2% per yr to 2032, primarily on account of rising demand for {custom} automobiles. However how is additive manufacturing used? What are its benefits?
To reply these questions, we’ve chosen to focus on European automobile producers who use 3D printing, whether or not for the manufacturing of completed components, practical prototypes, tooling and even customization parts. Labeled by nation, you’ll discover a non-exhaustive listing of manufacturers which have developed automotive 3D printing tasks. Don’t hesitate to ship us your feedback, as this map is certain to evolve!
Map of European automakers utilizing 3D printing. Click on HERE to enlarge and obtain
Germany
For over a century, the German automotive business has been internationally famend for its high quality and innovation. Additive manufacturing is deeply rooted right here, with iconic manufacturers akin to BMW and Volkswagen utilizing 3D printing for 20 to 30 years. Right this moment, different main automotive names akin to Porsche, Audi, Mercedes-Benz and Opel are additionally harnessing the advantages of additive manufacturing, with their very own 3D printing and improvement facilities.
This know-how performs an important position all through the manufacturing chain, from analysis and improvement (R&D) to the meeting and restoration of basic vehicles. An increasing number of automotive parts, akin to physique and transmission components, in addition to inside parts like Audi’s breathable seat, at the moment are made utilizing 3D printing.
To fulfill these wants, a wide range of printing applied sciences and supplies are employed. For instance, Porsche used laser powder mattress fusion in 2020 to print an electrical motor housing, and benefited from options supplied by SLM Options to optimize the topology and significantly cut back the load of the half. BMW, in the meantime, deploys a variety of applied sciences all through its manufacturing chain, together with SLS, large-scale printing and, extra just lately, WAAM. In 2023, BMW’s Oberschleißheim middle produced 300,000 components utilizing additive manufacturing.
Moreover, Volkswagen, which focuses totally on steel 3D printing at its Wolfsburg website, additionally introduces its trainees to FDM know-how and its advantages at its Emden campus. Mercedes-Benz, in the meantime, makes use of 3D printing primarily for upkeep, having arrange cell 3D printing facilities with digital twins to supply spare components domestically for its buses (Daimler Truck & Buses).
Picture Credit: BMW
France
In France, Renault, Alpine, Peugeot and Bugatti are simply among the producers who’ve built-in and use additive manufacturing of their each day work. The functions are fairly totally different from one group to a different, merely due to the positioning of every model. Bugatti, for instance, depends on 3D printing to enhance the efficiency of its hypercars, and thus more and more light-weight parts. Just lately, the producer imagined a chassis designed utilizing steel 3D printing, which enabled the discount of the load of the suspension by 45%. It additionally used laser powder mattress fusion to fabricate the world’s largest 3D-printed brake caliper in titanium.
Renault, for its half, is involved in internalizing these applied sciences. It has developed a printing middle in Flins that brings collectively totally different applied sciences – FDM, Multi Jet Fusion, in addition to post-processing options.The producer prints each practical prototypes and completed components – for instance, customizable parts for the inside of sure vehicles, or the inside mirror cowl for the brand new Alpine A110 R, a restricted collection of 900. In an unique interview, Renault commented, “In 2020, the group started to ask itself whether or not it made sense to 3D print components in its automobiles.This reflection was carried out throughout the whole worth chain and with all our manufacturers, and quite a few suppliers have been consulted. Right this moment, we’re organizing the corporate round this 3D printing exercise for manufacturing automobile components.”
Lastly, Peugeot makes use of additive manufacturing to design a few of its automobile components. So far as we all know, the automaker works with numerous service suppliers, and has maybe invested in a couple of workplace machines for speedy prototyping.
On the left, a 3D-printed spoiler help from Bugatti; on the proper, a custom-made half for the inside of the Peugeot 308.
Spain
Just a few years in the past, 3D printing was nonetheless underdeveloped within the automobile manufacturing sector in Spain. Right this moment, nonetheless, the automotive business is on the forefront of the adoption of additive applied sciences for part manufacturing. In accordance with a report by Sernauto, Spain is the fourth largest producer of automotive parts in Europe, with over 1,000 firms within the sector. Manufacturers akin to SEAT, CUPRA and LIUX at the moment are utilizing 3D printing of their processes. SEAT and CUPRA, members of the Volkswagen Group, have additive manufacturing facilities the place they exploit numerous 3D applied sciences akin to Multi Jet Fusion, SLS, FDM and PolyJet. SEAT specifies that 80% of the components produced are prototypes, the remaining being parts and tooling.
However, LIUX is a Spanish model born with the ambition to remodel the electrical automobile business utilizing progressive applied sciences.One in all its most outstanding developments is the LIUX Animal, a 3D-printed electrical automobile constructed from recycled or plant-based supplies. Because of additive manufacturing, the corporate has succeeded in lowering vitality consumption by 70%, lightening the physique, dashing up manufacturing instances and chopping CO2 emissions.
Picture Credit: SEAT
The UK
When folks consider automobile manufacturing in the UK, what involves thoughts is undoubtedly premium, basic automobiles with main producers like Bentley, Jaguar and Rolls-Royce. And these producers are more and more adopting additive manufacturing applied sciences together with the above-mentioned in addition to Bentley, McLaren and MINI.
One of many fundamental methods the place we’re seeing using 3D printing amongst these manufacturers suits in properly with impression that the concept the British automotive business is a hotbed for luxurious: we’re speaking after all in regards to the creation of customizable and distinctive sportscars. Take for instance the case of Aston Martin.
The posh model has been a long-time adopter of 3D printing. It first turned to polymer extrusion again in 2021 and extra just lately utilizing carbon fiber FDM and aluminum steel 3D printing to assist in the event of the brand new DBR22. However that’s not the one instance. Though Rolls Royce might be finest recognized for its use of steel additive manufacturing for functions in aerospace, the corporate has additionally built-in steel and polymer 3D printing into its vehicles, with one latest instance being the specifically commissioned La Rose Noire which included a 3D printed decrease consumption manifold. This customization isn’t just for the wealthy both, MINI additionally had a 3D printing customization service for its vehicles, though it has since been discontinued.
After all, customization isn’t the one approach that these automobile firms are utilizing additive manufacturing. Bentley has its personal 3D printing capacities at its Crewe manufacturing unit. In 2021, they produced 15,000 parts and the services have been expanded in 2022 with functions together with prototyping, personalization and low quantity manufacturing. Equally, Jaguar was one of many first adopters in 2020 with a AM middle used for its vehicles, together with for together with the Jaguar XE SV Challenge 8 which was one of many first automobiles to function end-use 3D printed components.
Final however not least, McLaren has adopted additive manufacturing to be used in its racing division with Stratasys in addition to a latest settlement with Divergent Applied sciences. Right here, AM will likely be on the core of the subsequent era of supercars. The opportunity of diminished weight and improved dynamic efficiency being the principle driver of the corporate’s adoption. Exhibiting clearly the big selection of functions that British automobile producers have discovered for additive manufacturing within the automotive sector.
A McLaren racecar made with the assistance of Stratasys’ FDM and PolyJet applied sciences (photograph credit: McLaren)
Italy
In accordance with a latest report by the Rome Enterprise College, Italy produces 540,000 vehicles a yr (2023 figures). The report additional expalins that “The Italian automotive sector is characterised by a excessive diploma of fragmentation: though many micro-businesses (…) are current in massive numbers, 85% of gross sales are generated by massive firms.” It is usually these massive firms that focus the principle investments in new applied sciences, supplies and merchandise.
All the foremost Italian automakers, akin to Ferrari, Maserati, Lamborghini, Pagani, Dallara, in addition to Fiat and Alfa Romeo, have adopted or experimented with 3D printing.They’re now investing on this know-how for the creation of prototypes and closing components.Over time, additive manufacturing has enabled them to enhance the manufacturing and efficiency of their automobiles. What’s extra, firms in Italy’s Motor Valley are synonymous with luxurious and customization, the latter being one of many fundamental benefits supplied by additive applied sciences.
Particularly, Ferrari has experimented with steel 3D printing, utilizing DMLS know-how to fabricate higher-performance steel parts and aerodynamic parts for its automobiles, together with its Formulation 1 vehicles. One other instance is the Maserati MCXtrema, whose physique was designed utilizing 3D printing. Maserati additionally makes use of PolyJet know-how to customise the seats of its automobiles.
Lamborghini made its mark a couple of years in the past with the Sián, which contains additive manufacturing. This selection was made not solely due to the power to supply parts in small batches, however above all due to the huge potentialities for inside and exterior customization. Parts akin to air intakes, connectors, brackets and housings are manufactured in 3D utilizing SLS polymer know-how. The Italian automotive scene additionally consists of more moderen firms, akin to XEV, which has developed the Yoyo, a small electrical automobile with a 3D-printed physique, providing extra dynamic and sustainable mobility.
The Sián incorporates 3D-printed components (photograph credit: Lamborghini)
Sweden
The Swedish automotive business, represented by famend manufacturers akin to Volvo and Koenigsegg, is more and more adopting 3D printing know-how in its manufacturing processes. Volvo, a significant participant on the world market, has built-in the progressive chilly spray method developed by Titomic. This know-how permits thick layers of particular metals to be deposited on surfaces with out melting them. It’s significantly utilized by Volvo Vehicles for the upkeep, restore and overhaul of its heavy-duty automobile engines.
Koenigsegg, well-known for its hypercars, integrates 3D printing specifically within the manufacture of its hybrid automobiles, with FDM and resin printers to supply 1000’s of components.Their founder and CEO, Christian von Koenigsegg, says they make their very own resin for these processes.He says: “We make housings for digital controllers, nozzles for sprayers, fins, and different high-temperature components.” Koenigsegg additionally makes use of 3DPrinterOS software program to enhance its manufacturing course of, utilizing 3D printing for speedy prototyping and part testing, making manufacturing extra environment friendly and cost-effective.
Picture Credit: Koenigsegg
The Czech Republic
ŠKODA AUTO, a member of the Volkswagen Group and the biggest employer within the Czech Republic, has been utilizing 3D printing for a number of years to develop new fashions, produce prototypes, manufacture spare components and take a look at supplies in mass manufacturing. On the fundamental plant in Mladá Boleslav, the manufacturing and logistics division has a 3D printing farm with some fifty printers, together with Prusa fashions.This facility permits advanced components to be produced shortly and precisely.
Because of the success of this initiative, 3D plastic printing has been prolonged to different websites. This know-how permits ŠKODA technicians to develop and match prototypes and spare components in-house, lowering dependence on exterior components. The outcomes are clear: manufacturing is quicker, extra environment friendly and more cost effective. Michael Oeljeklaus, Head of Manufacturing and Logistics at ŠKODA AUTO, expands: “We use 3D printing to create parts and instruments quicker, extra effectively and at decrease price, profiting from Business 4.0 applied sciences.”
Austria
Purple Bull Racing is more and more integrating additive manufacturing into Formulation 1 to cut back automobile weight and optimize efficiency. In partnership with Hexagon Manufacturing Intelligence, which has been working with the crew for 18 years, 3D printing is getting used to cut back manufacturing errors by 50%. Purple Bull Racing makes use of digital twins and simulations to check vehicles earlier than producing bodily prototypes. The design course of makes use of CAD software program, whereas manufacturing relies on SLA know-how.This allows prototypes and components to be created quickly, dashing up improvement and rising reliability.
“With out 3D printing, we wouldn’t be capable of keep aggressive on the observe,” says Purple Bull Racing’s head of engineering. 3D printing can be getting used to fabricate drones to evaluate efficiency on the racetrack, giving the crew a strategic benefit by facilitating the speedy integration of improvements. Synthetic intelligence additionally helps optimize the design course of and adapt automobiles to totally different climates.
Picture credit: Purple Bull Racing
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*Cowl Picture Credit: Sernauto
