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How To 3D Print Replacement Car Parts [2022 Guide]
If you're looking to create your own car parts, you can do so with ease. Here is a guide on how to 3D print replacement car parts very cheap.
By Justin Evans
As 3D printing technology grows more popular, hobbyists and automotive industry leaders alike are starting to 3D print car parts as an alternative to expensive repairs and manufacturing.
This may seem unbelievable to people outside of the 3D printing space, but it is true. 3D printers can create all kinds of car parts, and they work just as well as traditionally manufactured parts.
There are plenty of reasons why people do this. They may want to personalize their car, make their car lighter, or just replace a part quickly without needing to pay an excessive amount for it.
For people who want to get into it, it is a lot easier than it looks.
Table of ContentsShow
What Kind of Parts Can You Make With 3D Printers?
There are several types of parts that you can use 3D printing to manufacture:
- Cosmetic customization (rear-view mirrors, cup holders, custom frames)
- Small parts (lids, valves, specialized parts)
- Larger parts (grills, dashboards)
While you can make powerful parts with 3D printing (like with carbon fiber), it is not recommended for making internal car parts. These parts must deal with excessive heat or pressure and require a specialized manufacturing process.
So long as you keep the part, your intended material, and what that part is used for in mind, the sky is the limit as far as what you can create.
What Kinds of 3D Printers Are Best for 3D Printing Car Parts?
When 3D printing car parts, the ideal printer can vary depending on what you are trying to print.
For most things, an inexpensive basic printer is fine. Plenty of car parts are small and simple and should not need a heavy-duty machine to do the lifting.
If you plan on printing more complex parts or want intricate engravings on your customized parts, you may want to use a higher-end model that can handle that.
What Materials Should You Use?
There are plenty of materials you can use to 3D print your car parts, but the rule of thumb is they should be durable, lightweight, and flexible.
A few standout materials are:
- TPU (shock-absorbent, flexible, and durable)
- Polypropylene (great for airflow and fluid systems)
- Nylon PA11 (great if you are worried about sustainability)
- Polyamide 6 (heat resistant)
What material you use depends entirely on what part you want to make, so always do your due diligence and research what materials work best for each part before you start printing.
How Do You Go About 3D Printing Car Parts?
3D printing car parts seems complex, but when you get down to it, it is a simple process that only requires a few steps.
Make or Find a Scale Model
This is the most important step of the entire process.
A high-quality 3D printed car part relies on using the proper material and creating it from a good model.
You can set up your scale model in one of two ways. You can make the model yourself using a 3D modeler or find a model online. If you are not confident in your 3D modeling skills, it may be best to find an online model rather than make it yourself.
Many websites offer 3D models for parts that you can download and use with your 3D printer. Make sure the model is from a reputable source for the best results.
Pick Your Material
After picking out your model, the next step is to pick what material you want to use. This will depend entirely on what part you are making and your specific needs.
Remember, materials are not a one-size-fits-all solution. Make sure the material you choose matches your part’s use (heat resistance or flexibility, for example). If you make a part with the wrong material and install it, it can break or damage your car.
Also, keep in mind that just because you can theoretically make engine parts with 3D printing does not mean that you should.
Print the Part
After you have your model and material, it is time to make your part. Make sure the parameters are set the way you want them and double-check everything before printing. Follow the instructions based on your specific printer.
Finishing Touches
Once your part is printed, it is time to add any finishing touches. This is when you paint any small details, like numbers on a knob, or coat the part in another material for a better finish.
You should also use this time to check over the part and make sure everything is up to standard. If there are any defects or issues with the part, you will need to start over.
Install the Part
After printing the part, it is time to install it. This is simple for a part like a cup holder or knob — just pop it in and see if it fits.
If you 3D printed a part like a grill or a dashboard, try going on a test drive first and see how it holds up under a stress test. If it looks like it is not holding up well, it’s time to go back to the drawing board.
What if You Don’t Want to Do It Yourself?
Sometimes 3D printing car parts is not feasible for everyone. A person may want to 3D print a part, but they do not have access to a printer or are not confident in their 3D modeling skills.
In this case, you may want to consider hiring a business that specializes in 3D printing car parts. Be sure to check the business’ rates, selection, and reviews before committing.
Conclusion
3D printing car parts is an easy way to customize and repair your car without breaking the bank. With the right model, materials, and plenty of patience, 3D printing your own parts is a reliable way to take care of your car and make it your own.
There are no limits to what can be done with 3D printing, whether you do it yourself or hire someone else to make the parts for you.
Car parts made with PA-CF Low Warp
There are as many uses for our filaments as there are 3D printers and users in this world. We love to come across great applications for our materials.
Applications we could not think of when we developed and produced the filaments. Or could think of but never thought we would actually see it. Enter John Pham from Brisbane, Australia, who prints car parts with our PA-CF Low Warp filament.
3D printed velocity stacks, all images made by John
We came across these prints on Reddit and contacted John about the amazing quality and practical use of his prints.
Check out the original Reddit post!
John considers himself a hobbyist and has printed about 10kg of PA-CF Low Warp. He has declared it his favorite filament so far to use.
Spacer and velocity stacks, aluminium inserts used to add strength to the parts
John is a 3D printing enthusiast who happens to love cars. He adds: “I took this opportunity to try design and print as many parts for my modified Mazda MX-5 as possible. My main printer is a modified Tevo Tornado with a E3D Titan Aero hotend/extruder and 0.
5 mm NozzleX, I print at 0.2mm and 0.1mm layer height depending on the parts function. My printing material of choice for functional car parts has always been carbon fiber nylon, and in my opinion colorfabb PA-CF produces the best results. Consistent printing results for myself and customers, good strength, excellent resistance to heat, fuels and oils. It also prints very easily, purple gluestick on 55C glass, no warping, flawless supports, excellent surface finish and dimensional accuracy.”
As you can see, John has quite the skills to print with our engineering grade filament. PA-CF Low Warp is a carbon fiber infused polyamide material with the mechanical properties of a PA6 and excellent printability because of extremely low warp.
The material can be printed on desktop FFF 3D printers, which have a temperature range of at least 260°C on the hot-end and the ability to mount an abrasive resistant nozzle. PA-CF Low Warp excels in tensile and impact strength and allows continues use at 120°C while retaining sufficient properties for the intended application.
The formulation has been modified to reduce uptake of moisture and it also takes about 4 times longer to reach the saturation point compared to unmodified PA6. This makes PA-CF Low Warp less affected by moisture then most other nylon filaments available in the market.
It’s not only the velocity stacks that John printed: “I’ve used colorfabb PA-CF to print intake velocity stacks, bulkhead plates, side mirror mount, bonnet prop, work jigs, mounting brackets, 3D printer parts, and electrical connector housings.”
Visit John’s blog for more of his work!
PA-CF Low Warp was developed and released two years ago with LEHVOSS Group. The material shows good results when printed at ambient temperature, or cold bed. The advised processing temperature for this material is set between 260C and 280C. You can find more information about the printability of PA-CF Low Warp on our dedicated landing page.
PA-CF Low Warp is available at colorFabb and ships worldwide from stock.
Curious how to print with PA-CF Low Warp? Here is our tutorial!
Disclaimer: 3D printing is subject to various factors: material, processing, printer, settings, etc. Using printed parts like car parts or other parts that are used in real life are at the user’s own risk. We recommend expert level printing, like this example, and extensive testing before use.
3d printing car parts colorfabb functional parts pa-cf low warp tevo tornado
5 ways 3D printing is changing the automotive industry / Sudo Null IT News
You can't buy a fully 3D printed car in a car dealership yet, but additive technologies have been used in car design for many years. Every year, especially in recent years, 3D printing is taking an increasingly important place at all stages of production.
This is evidenced by the rapid growth of 3D printing market share in automotive manufacturing, which is projected to reach $2.5 billion by 2023.
For example, luxury car companies including Bentley, Porsche, BMW and Ferrari are using 3D printing to create custom car interior parts. GM, Volvo, Ford are using 3D printing to produce tooling to save money, improve designs and reduce delivery times. 3dprinting.com If the first 3D printers cost about $20,000, now you can find 3D equipment for $100. Now companies can, with the help of additive technologies, produce the necessary components directly at their own enterprises and not depend on suppliers.
With new materials, 3D printers can print high-precision, functional end parts. Additive technologies facilitate the production of custom products and increase productivity.
But this is only the beginning of the journey. Here are five key ways 3D printing is driving innovation in the automotive industry, from car design to production.
Plus one bonus.
1. Changing the prototyping process
It was with the manufacture of prototypes that the use of 3D printers in the automotive industry began. 3D printed prototypes took much less time than traditional methods required.
Using Raise3D 3D printers and ideaMaker software, Crazy Grandpa Garage was able to automate the process of creating custom car parts. Production costs have been reduced by 50%, design reliability has improved significantly, and lead time has been reduced by 83%. The parts now come out very well fitted to the car.
Source: facebook.com
Using 3D printing, car designers can quickly prototype individual parts or assemblies, from interior detail to dashboard, or even full-size car models. Thanks to 3D prototyping, the initial idea quickly turns into a physical embodiment of the concept - a conceptual model. The concept can then be developed into full-featured, high-fidelity prototypes, and after several validation steps, mass production begins.
For the automotive industry, getting through these steps quickly is vital, and the entire downtime of an automobile production line in just an hour is very costly for the company.
For example, the assembly plant of the US car manufacturer General Motors claims to have saved more than $300,000 by purchasing a 3D printer in 2016.
Ringbrothers designers and engineers are not dependent on third parties to implement laser stereolithography (SLA) in their facility. The cost is reduced, the development time is reduced. Source: formlabs.com
Hose for Eventuri BMW M4, Source: ultimaker.com
Traditional prototyping was time-consuming and costly, in part because the product went through more iterations. With 3D printing, you can create high-quality prototypes in one day and at a much lower cost. More examples.
The Ford Fiesta ST with 3D printed parts, ext. SEMA 2016, ultimaker.com
For example, General Motors has partnered with Autodesk to produce low cost, lightweight automotive parts using 3D printers.
Tools, fixtures and fittings can now be produced at a fraction of the cost, according to Autodesk. For example, a 3D printed tool used to align engine and transmission ID numbers costs less than $3 at General Motors. A traditionally produced instrument will cost $3,000. In addition, downtime due to faulty tools can be significantly reduced as new tools are produced in-house.
2. Creation of non-standard and complex parts
Daihatsu, Japan's oldest car manufacturer, launched a project in 2016 to customize its Copen model.
Source: 3dprint.com
In partnership with Stratasys, Daihatsu customers can design and order custom 3D printed panels for their front and rear bumpers with a choice of over 15 basic patterns in 10 different colors.
Source: 3dprint.com
In Europe, the BMW MINI brand also uses 3D printing to create personalized car parts. Since the beginning of 2018, MINI customers have been able to personalize various trim elements such as the instrument panel, LED treadplates and illuminated bumpers, as well as choose from different colors and textures.
These parts are then 3D printed using a range of technologies from DLS Carbon to SLS.
Source: formlabs.com
Volkswagen Motorsport's I.D. R Pikes Peak is designed with over 2000 3D printed test parts.
Source amfg.ai
The use of 3D printers makes it possible to experiment in the development of non-standard designs, reduces the cost of their production. Long production processes for custom-made products are becoming much shorter.
Ringbrothers uses 3D printing to create customized end pieces such as ventilation grilles. Source: formlabs.com
Large companies are merging 3D printing technologies with traditional manufacturing methods. Volkswagen has recreated its iconic 1962 Microbus by replacing the petrol engine with a 120 hp electric one. The Type 20 concept electric minivan has received many improvements using 3D printed parts. These improvements include cast aluminum wheels.
Even the wheel hubcaps, while looking like stamped steel, are actually printed on a Formlabs SLA 3D printer, then electroplated and polished.
Source: formlabs.com
Formlabs Form 2 SLA 3D printer specifications
Bentley has used cutting-edge metal 3D printer technology to produce a grille, side vents, door handles and exhaust pipes much more complex than those used on current production models.
Bentley used metal 3D printing to create intricate micron precision parts. Source: formlabs.com
Source: youtube.com
3D printing has also made it possible to create parts that could not be made in any other way.
Bugatti's monobloc brake caliper is a prime example. For some components, Bugatti would have preferred titanium due to its high performance, but processing this metal with traditional methods is expensive and difficult. 3D printing has allowed Bugatti to produce a titanium alloy brake caliper.
Due to the thin walls, the caliper turned out to be very light - almost two times lighter than forged aluminum. At the same time, the strength of the 3D-printed monoblock is superior to that of aluminum. The 3D printed titanium monoblock has a tensile strength of 1250 N/mm2. This means that a force of just over 125 kg will be applied per square millimeter of this titanium alloy without tearing the material. The new titanium caliper is 41 cm long, 21 cm wide and 13.6 cm high and weighs only 2.9kg compared to currently used aluminum, which weighs 4.9 kg.
Source: youtube.com
The Bugatti brake monoblock is the industry's largest functional 3D printed titanium component for a car. Source: formlabs.com
3. Tool making
Various devices help to facilitate and speed up the production and assembly processes, improve the safety of workers. Automotive factories and component suppliers use a large number of non-standard tooling that is specifically designed and optimized for end use.
As a result, a lot of non-standard equipment and tools are made, which increases production costs.
This 3D protective wheel disc was purchased for 800 euros but can now be printed for just 21 euros. Tool development time has been reduced from 56 to 10 days.
Source: ultimaker.com
Delegating custom tooling and fixtures to service providers who machine parts from solid metal or plastic stock can delay production by weeks.
For example, the development and prototype of a commutator motor using traditional manufacturing methods can take up to four months and cost about half a million dollars. Thanks to 3D printing, Ford was able to develop several variants in just 4 days and 99.4% cheaper - only $3,000.
Source: youtube.com
Additive technologies allow you to complete the task in a few hours and significantly reduce costs compared to ordering from a third-party enterprise. Since increasing the complexity of a 3D printed model does not incur additional costs, products can be better optimized for their application.
New elastic materials for 3D printing in many cases allow you to print plastic parts instead of metal or create prototypes on a 3D printer to test the tool before using it in production
Gradually, the production of 3D printed accessories and tools is becoming one of the largest applications of additive technologies.
Pankl Racing Systems uses 3D printed fixtures to fasten workpieces to a conveyor belt. Source: formlabs.com
For example, Pankl Racing Systems uses a stack of multiple Formlabs SLA 3D printers to make critical manufacturing tools. The multi-stage production of parts for transmissions on automatic lathes requires a series of fixtures and tools designed for each specific part.
With the help of 3D printing, Pankl's engineers have reduced the production time for the aids by 90%, from 2-3 weeks to around 20 hours. Costs were also reduced by 80-90%, saving $150,000.
The transition to 3D printing has enabled Volkswagen Autoeuropa to cut tooling development costs by 91% and cut tooling times by 95%.
4. Troubleshooting spare parts
Spare parts have always been a problem for the automotive industry. The demand for them is either there or not, so the production of spare parts is not economically viable, and the storage of pre-fabricated replacement components is also costly. But if there are no repair parts available, difficulties arise and the main product becomes less valuable.
3D printing could solve the problem of parts in the automotive industry in many ways. The main factors are printed materials, which can match the characteristics of traditional materials used in parts and be cost-effective. There are prerequisites for this.
Using computer-aided design, drawings of all parts can be stored digitally, so there is no need to store the parts themselves. The parts needed by the client can be printed on a 3D printer right in the workshop.
Even obsolete parts whose blueprints have not survived can in principle be recreated by making a 3D scan of existing parts of this type and applying reverse engineering (reverse engineering).
You can read more about this on our blog. Old projects can take on new life. There are many lovers of vintage cars, with the help of 3D printing it would be possible to create parts for them.
Ringbrother 3D printed the Cadillac emblem for a custom built old car. Source: formlabs.com
5. Production of standard parts
As 3D printers and materials for 3D printing become more affordable, a gradual transition to the production of mass-produced automotive parts using additive technologies is possible.
3D printing makes it possible to combine components into a single whole. Let's say there is a mechanism assembled from six or seven car parts that can be combined into one printed part. It will save time and assembly costs. With 3D printing, it is also possible to reduce the weight of the combined assembly, as a result, the car will use fuel more efficiently.
3D Systems has designed an advanced exhaust pipe for a sport bike.
In the image below, you will see 20 sheet metal and hydroformed parts needed to assemble the original exhaust pipe. On the right is a monolithic exhaust pipe that does not require assembly, made using metal 3D printing.
Source designnews.com
The 3D printed tube was produced using Grade23 titanium in just 23 hours, compared to three weeks for traditional production. Design development time reduced from 6 weeks to 6 days. Additive manufacturing also eliminates the need for tooling, fixtures, multiple welding and multiple inspections.
Geometry optimization has reduced the amount of material needed for maximum productivity. All elements of the original exhaust pipe are incorporated into the new design and, when printed with a typical wall thickness of 0.5mm, the 3D printed exhaust pipe is about 25% lighter than the original one.
A wide range of 3D printing materials is starting to meet the requirements of various vehicle components. Since additive methods reduce costs compared to traditional methods (such as molding and injection molding), it makes a lot of sense from a production and financial point of view to further introduce 3D printing into the production of basic parts.
Volkswagen, one of the world's largest and most innovative car manufacturers, is using an HP Metal Jet 3D printer to produce high-performance functional parts with special design requirements, such as shift knobs and mirror mounts. Volkswagen's long-term plans to work with HP include accelerating the production of mass-customized parts such as key rings and exterior nameplates.
Source: youtube.com
+1. 3D printed cars
While 3D-printed cars have yet to hit the market, there are some interesting designs and concepts that can suggest a possible direction for the automotive industry.
Light Cocoon . German engineering firm EDAG was clearly inspired by nature to create the 3D printed supporting structure of the Light Cocoon concept car. The frame resembles the veins of a tree leaf or its branch. Despite the fact that the design of the EDAG took less material than a conventional frame, all the strength requirements for structurally significant components are met.
Outside, the case is covered with a lightweight and durable waterproof fabric.
The cover protects the EDAG Light Cocoon from bad weather and gives the car a unique personality. Source: formlabs.com
Blade . Blade ("Blade") announced as "the world's first 3D-printed supercar." It meets supercar standards but is made from inexpensive materials: carbon fiber tubes and aluminum rods, combined with 3D printed metal parts. Blade turned out to be very light and does not take long to assemble.
The world's first 3D printed Blade supercar. Source: formlabs.com
Strati . The American company Local Motors 3D printed and assembled the Strati electric car right at the exhibition stand, in just 44 hours. Most of the components were printed - the body, seats, interior parts. A car is made up of less than 50 assemblies, far fewer than the thousands of parts that go into a traditional car. The company intends to reduce the print time to 10 hours.
The Strati from Local Motors consists of less than 50 individual parts*. Source: formlabs.com
LSEV. Developed by the Italian company XEV, the LSEV could be the first in the 3D printed electric vehicle market when it goes on sale. The 3D printed chassis, seats, windshield and all visible parts of the LSEV. Thanks to the active use of 3D printing, the number of components was reduced from 2000 to just 57, resulting in a very lightweight design. The electric car weighs only 450 kg.
The LSEV is the first 3D printed electric vehicle to hit the market in 2020. Source: formlabs.com
While most of these and many other 3D printed car projects remain at the concept stage, the extent to which 3D printing has penetrated various areas of the automotive industry is striking. In some cases, additive technologies provide new opportunities for design and production, in others they reduce production costs and save time.
See also:
3D printer and CNC race car making
3D scanning of cars in tuning and repair
5 ways 3D printing is changing the automotive industry
Photo source .
com
An article from formlabs.com adapted and supplemented for you by Top 3D Shop.
You can't buy a fully 3D printed car at a car dealership yet, but additive technologies have been used in car design for many years. Every year, especially in recent years, 3D printing is taking an increasingly important place at all stages of production. This is evidenced by the rapid growth of 3D printing market share in automotive manufacturing, which is projected to reach $2.5 billion by 2023.
For example, luxury car companies including Bentley, Porsche, BMW and Ferrari are using 3D printing to create custom car interior parts. GM, Volvo, Ford are using 3D printing to produce tooling to save money, improve designs and reduce delivery times.
Source 3dprinting.com
3D printing is constantly emerging new opportunities, it is becoming more accessible. If the first 3D printers cost about $20,000, now you can find 3D equipment for $100. Now companies can, with the help of additive technologies, produce the necessary components directly at their own enterprises and not depend on suppliers.
With new materials, 3D printers can print high-precision, functional end parts. Additive technologies facilitate the production of custom products and increase productivity.
But this is only the beginning of the journey. Here are five key ways 3D printing is driving innovation in the automotive industry, from car design to production. Plus one bonus.
1. Changing the prototyping process
It was with the production of prototypes that the use of 3D printers in the automotive industry began. 3D printed prototypes took much less time than traditional methods required.
Using Raise3D 3D printers and ideaMaker software, Crazy Grandpa Garage was able to automate the process of creating custom car parts. Production costs have been reduced by 50%, design reliability has improved significantly, and lead time has been reduced by 83%. The parts now come out very well fitted to the car.
Source: facebo ok.com
Using 3D printing, car designers can quickly prototype individual parts or assemblies, from interior detail to dashboard, or even full-size car models.
Thanks to 3D prototyping, the initial idea quickly turns into a physical embodiment of the concept - a conceptual model. The concept can then be developed into full-featured, high-fidelity prototypes, and after several validation steps, mass production begins. For the automotive industry, getting through these steps quickly is vital, and the entire downtime of an automobile production line in just an hour is very costly for the company.
For example, the assembly plant of the US car manufacturer General Motors claims to have saved more than $300,000 by purchasing a 3D printer in 2016.
Ringbrothers designers and engineers are not dependent on third parties to implement laser stereolithography (SLA) in their facility. The cost is reduced, the development time is reduced. Source: formlabs.com
Tailpipes for BMW M4 by Eventuri, Source: ultimaker.com
Traditional prototyping was time consuming and costly, in part because the product went through more iterations.
With 3D printing, you can create high-quality prototypes in one day and at a much lower cost. More examples.
The Ford Fiesta ST with 3D printed parts, ext. SEMA 2016, ultimaker.com
For example, General Motors has partnered with Autodesk to produce low cost, lightweight automotive parts using 3D printers. Tools, fixtures and fittings can now be produced at a fraction of the cost, according to Autodesk. For example, a 3D printed tool used to align engine and transmission ID numbers costs less than $3 at General Motors. A traditionally produced instrument will cost $3,000. In addition, downtime due to faulty tools can be significantly reduced as new tools are produced in-house.
2. Creating custom and complex parts
Daihatsu, the oldest car manufacturer in Japan, launched a project in 2016 to customize its Copen model.
Source: 3dprint.com
In partnership with Stratasys, Daihatsu customers can design and order custom 3D printed panels for their front and rear bumpers, with a choice of over 15 basic patterns in 10 different colors.
Source: 3dprint.com
In Europe, the BMW MINI brand also uses 3D printing to create personalized car parts. Since the beginning of 2018, MINI customers have been able to personalize various trim elements such as the instrument panel, LED treadplates and illuminated bumpers, as well as choose from different colors and textures. These parts are then 3D printed using a range of technologies from DLS Carbon to SLS.
Source: formlabs.com
Volkswagen Motorsport's I.D. R Pikes Peak is designed with over 2000 3D printed test parts.
Source amfg.ai
The use of 3D printers makes it possible to experiment in the development of non-standard designs, reduces the cost of their production. Long production processes for custom-made products are becoming much shorter.
Ringbrothers uses 3D printing to create customized end pieces such as ventilation grilles. Source: formlabs.com
Large companies are merging 3D printing technologies with traditional manufacturing methods.
Volkswagen has recreated its iconic 1962 Microbus by replacing the petrol engine with a 120 hp electric one. The Type 20 concept electric minivan has received many improvements using 3D printed parts. These improvements include cast aluminum wheels. Even the wheel hubcaps, while looking like stamped steel, are actually printed on a Formlabs SLA 3D printer, then electroplated and polished.
Source: formlabs.com
Formlabs Form 2 SLA Specifications
Source: top3dshop.ru
The Bentley Speed 6 is another example. Bentley has used cutting-edge metal 3D printer technology to produce a grille, side vents, door handles and exhaust pipes much more complex than those used on current production models.
Bentley used metal 3D printing to create intricate micron precision parts. Source: formlabs.com
Bugatti's monoblock brake caliper is a prime example.
For some components, Bugatti would have preferred titanium due to its high performance, but processing this metal with traditional methods is expensive and difficult. 3D printing has allowed Bugatti to produce a titanium alloy brake caliper. Due to the thin walls, the caliper turned out to be very light - almost two times lighter than forged aluminum. At the same time, the strength of the 3D-printed monoblock is superior to that of aluminum. The 3D printed titanium monoblock has a tensile strength of 1250 N/mm2. This means that a force of just over 125 kg will be applied per square millimeter of this titanium alloy without tearing the material. The new titanium caliper is 41 cm long, 21 cm wide and 13.6 cm high and weighs only 2.9kg compared to currently used aluminum, which weighs 4.9 kg.
The Bugatti Brake Monobloc is the industry's largest functional 3D printed titanium vehicle component.
Source: formlabs.com
3. Tool and fixture making
A variety of fixtures help make manufacturing and assembly processes easier and faster, and improve worker safety. Automotive factories and component suppliers use a large number of non-standard tooling that is specifically designed and optimized for end use. As a result, a lot of non-standard equipment and tools are made, which increases production costs.
This 3D protective wheel disc was purchased for 800 euros but can now be printed for just 21 euros. Tool development time has been reduced from 56 to 10 days.
Source: ultimaker.com
Delegating custom tooling and fixtures to service providers who machine parts from solid metal or plastic stock can delay production by weeks.
For example, the development and prototype of a commutator motor using traditional manufacturing methods can take up to four months and cost about half a million dollars. Thanks to 3D printing, Ford was able to develop several variants in just 4 days and 99.
4% cheaper - only $3,000.
Additive technologies allow you to complete the task in a few hours and significantly reduce costs compared to ordering from a third-party enterprise. Since increasing the complexity of a 3D printed model does not incur additional costs, products can be better optimized for their application. New elastic materials for 3D printing in many cases allow you to print plastic parts instead of metal or create prototypes on a 3D printer to test the tool before using it in production.
Gradually, the production of 3D printed accessories and tools is becoming one of the largest applications of additive technologies.
Pankl Racing Systems uses 3D printed fixtures to fasten workpieces to a conveyor belt. Source: formlabs.com
For example, Pankl Racing Systems uses a stack of multiple Formlabs SLA 3D printers to make critical manufacturing tools.
The multi-stage production of parts for transmissions on automatic lathes requires a series of fixtures and tools designed for each specific part.
With the help of 3D printing, Pankl's engineers have reduced the production time for the aids by 90%, from 2-3 weeks to around 20 hours. Costs were also reduced by 80-90%, saving $150,000.
The transition to 3D printing has enabled Volkswagen Autoeuropa to cut tooling development costs by 91% and cut tooling times by 95%.
4. Solving problems with spare parts
Spare parts have always been a problem for the automotive industry. The demand for them is either there or not, so the production of spare parts is not economically viable, and the storage of pre-fabricated replacement components is also costly. But if there are no repair parts available, difficulties arise and the main product becomes less valuable.
3D printing could solve the problem of parts in the automotive industry in many ways.
The main factors are printed materials, which can match the characteristics of traditional materials used in parts and be cost-effective. There are prerequisites for this.
Using computer-aided design, drawings of all parts can be stored digitally, so there is no need to store the parts themselves. The parts needed by the client can be printed on a 3D printer right in the workshop.
Even obsolete parts whose blueprints have not survived can in principle be recreated by making a 3D scan of existing parts of this type and applying reverse engineering (reverse engineering). You can read more about this on our blog. Old projects can take on new life. There are many lovers of vintage cars, with the help of 3D printing it would be possible to create parts for them.
Ringbrother 3D printed the Cadillac emblem for a custom built old car. Source: formlabs.com
5. Production of standard parts
As 3D printers and materials for 3D printing become more affordable, a gradual transition to the production of mass-produced automotive parts using additive technologies is possible.
3D printing makes it possible to combine components into a single whole. Let's say there is a mechanism assembled from six or seven car parts that can be combined into one printed part. It will save time and assembly costs. With 3D printing, it is also possible to reduce the weight of the combined assembly, as a result, the car will use fuel more efficiently.
3D Systems has designed an advanced exhaust pipe for a sport bike. In the image below, you will see 20 sheet metal and hydroformed parts needed to assemble the original exhaust pipe. On the right is a monolithic exhaust pipe that does not require assembly, made using metal 3D printing.
Source: designnews.com
3D printed tube produced using Grade23 titanium in just 23 hours, it would take three weeks for traditional production. Design development time reduced from 6 weeks to 6 days. Additive manufacturing also eliminates the need for tooling, fixtures, multiple welding and multiple inspections.
Geometry optimization has reduced the amount of material needed for maximum productivity. All elements of the original exhaust pipe are incorporated into the new design and, when printed with a typical wall thickness of 0.5mm, the 3D printed exhaust pipe is about 25% lighter than the original one.
A wide range of 3D printing materials is starting to meet the requirements of various vehicle components. Since additive methods reduce costs compared to traditional methods (such as molding and injection molding), it makes a lot of sense from a production and financial point of view to further introduce 3D printing into the production of basic parts.
Volkswagen, one of the world's largest and most innovative car manufacturers, is using an HP Metal Jet 3D printer to produce high-performance functional parts with special design requirements, such as shift knobs and mirror mounts. Volkswagen's long-term plans to work with HP include accelerating the production of mass-customized parts such as key rings and exterior nameplates.
+1. 3D Printed Cars
Although complete 3D printed cars have not hit the market yet, some interesting designs and concepts suggest a possible direction for the automotive industry.
Light Cocoon. German engineering firm EDAG was clearly inspired by nature to 3D print the supporting structure of the Light Cocoon concept car. The frame resembles the veins of a tree leaf or its branch. Despite the fact that the design of the EDAG took less material than a conventional frame, all the strength requirements for structurally significant components are met. Outside, the case is covered with a lightweight and durable waterproof fabric.
The cover protects the EDAG Light Cocoon from bad weather and gives the car a unique personality. Source: formlabs.com
Blade . Blade ("Blade") announced as "the world's first 3D-printed supercar.
" It meets supercar standards but is made from inexpensive materials: carbon fiber tubes and aluminum rods, combined with 3D printed metal parts. Blade turned out to be very light and does not take long to assemble.
The world's first 3D printed Blade supercar. Source: formlabs.com
Strati . The American company Local Motors 3D printed and assembled the Strati electric car right at the exhibition stand, in just 44 hours. Most of the components were printed - the body, seats, interior parts. A car is made up of less than 50 assemblies, far fewer than the thousands of parts that go into a traditional car. The company intends to reduce the print time to 10 hours.
The Local Motors Strati consists of less than 50 individual parts*. Source: formlabs.com
LSEV . Developed by the Italian company XEV, the LSEV could be the first in the 3D printed electric vehicle market when it goes on sale. The 3D printed chassis, seats, windshield and all visible parts of the LSEV.
