Automotive AM: 3D printing & the vehicle industry

Additive manufacturing (AM), otherwise known as 3D printing, offers a range of new possibilities for innovative design and a highly customizable fabrication process in the automotive sector. Because 3D printing offers more flexibility, it is possible to reduce lead times and add complexity to parts, without excessive costs. As this technology becomes increasingly mainstream, sourcing professionals in the industry can look forward to a number of opportunities to capture more customers and offer something new to existing ones.

"The thirst for newer, better performing vehicles, as well as the need to optimize production and streamline supply chains and logistics, is … spiking. One technology that is helping to meet these challenges is 3D printing," writes analyst Astha Oriel in her rundown of automotive trends to watch in 2021. "Aside from its extensive use for rapid prototyping, the technology is also being used to produce tooling and end parts."

Auto giants are enthusiastic AM adopters

According to the recent Managing Automotive Technology Trends survey sponsored by global manufacturing services company Jabil, manufacturing technologies are also driving growth and change in the automotive industry. All of the survey participants expect AM to impact the vehicle manufacturing sector. Forty percent envision that 3D printing will help with mass production, 35 percent see value in using it for early prototyping and design, 21 percent think it will influence tooling, and 4 percent say it will support automotive service and maintenance.

Ninety-four percent of participants are planning to expand their 3D printing capabilities. About half expect to add this to their supply chains by outsourcing to partners, 47 percent plan to do so through acquisitions and 44 percent are investing in building in-house staff and infrastructure to support 3D printing.

Major auto industry names are among the early adopters. German automotive giant BMW, for example, uses additive manufacturing technologies to produce spare parts for its classic vehicles, tools, and even end-use parts.

Electric vehicles lead the way

Back in 2019, at the opening of its new engineering center in Silicon Valley, Volkswagen presented an electric version of its classic 1962 Combi camper van called the Type 20. The concept model featured a number of 3D printed components, including the steering wheel, mirror supports and wheels. Additive manufacturing allowed Volkswagen to reduce the overall weight of the van.

In that case, pairing AM with a fully electric vehicle was a way for VW to demonstrate its vision and capabilities for the future. But the decision may have been a prescient one, as EVs and AM look set to go hand-in-hand.

Kevin Quinn, General Motors' director of additive design and manufacturing, told Additive Manufacturing Media that "it's only a matter of time before generative design and AM become the primary technologies driving lighter parts for electric cars."

In electric vehicles, reduced weight is vital in lowering energy consumption and increasing range.

"The heavier the vehicle, the more battery capacity it needs to achieve established range and performance goals," explains a recent report by industry group AMFG.

But batteries are heavy, compared to other vehicle components, so adding battery capacity tends to increase vehicle weight disproportionately. It's a vicious cycle that means weight reduction – both overall vehicle weight and that of its components – is critical in an EV."

As of 2020, several EV projects are using 3D printing in development and production. AMFG cites Local Motors' Olli, a 3D-printed, autonomous electric shuttle designed for local, low-speed transportation.

Local Motors used some of the world's largest 3D printers – ORNL's Big Area Additive Manufacturing (BAAM) and Thermwood's Large Scale Additive Manufacturing (LSAM) machines – to produce most of Olli's components, including the roof and lower body of the vehicle.

As the EV industry continues to figure out how to best leverage 3D printing, the next decade will be pivotal to accelerating the use of the technology for sustainable vehicles.

Lighter parts

Buyers sourcing replacement parts and aftermarket upgrades will be interested in the possibility of lighter products – always a desirable factor for consumers looking to improve their vehicles' performance or efficiency.

In 2020, Porsche – which has been using additive manufacturing technology since the early 1990s – used 3D printing for the first time. The AM components were designed for the Porsche 911 GT2 and made from a specially designed aluminum alloy. 3D printing allowed Porsche to optimize the pistons and make them 10 percent lighter than the traditionally manufactured equivalent.

Personalization

Of significant interest for buyers in the automotive accessories business is the scope for personalization that additive manufacturing offers.

Lamborghini's Sian Roadster, for example, can be customized according to the client's tastes and preferences. The car's air vents are 3D printed, and customers can have their initials integrated into the design.

MINI, owned by the German automotive company BMW since 2000, has also begun offering customization on its cars thanks to additive manufacturing. MINI purchasers can modify their vehicles by designing the passenger-side sideband in the cockpit and the side inserts themselves. The pieces are then 3D printed at BMW's facility.

While this level of integration with the manufacturer is, at present, beyond the reach of most automotive industry sourcing professionals, suppliers using 3D printing will be able to offer highly customized accessories and components compatible with a wide range of vehicles, with the flexibility and reduced lead time of AM production enabling buyers to keep stocks down to a manageable level.

"Consumer interest in customization also opens opportunities for automakers and Tier 1 suppliers to utilize 3D printing to create a personalized look and feel for a given consumer," said Chad Morle, Vice President, Automotive and Transportation at Jabil. "Soon enough, buyers may be able to completely personalize their cars to reflect their individual preferences, beyond just the features they can select for their car."

What does this mean for sourcing?

Now is the time to talk to suppliers about their current and future capabilities for 3D printing. Knowing what is coming will enable you to plan an effective product offering and calculate your lead times and pricing based on the available materials, methods and MOQs. For those sourcing accessories and replacement parts in particular, the possibilities offered by AM technology in weight reduction and customization are not to be missed.