3D printing is changing how car parts are manufactured. It enables automotive manufacturers to build highly complex parts faster and with minimal waste.
This technology can be used to create prototypes, lightweight parts, and specialty items for obscure vehicle models as well as produce spare parts on demand.
This article will provide an overview of 3D printing automotive parts, including the use cases, step-by-step process, and some of the best 3D printing services to use.
Benefits of 3D Printing Automotive Parts
When it comes to 3D printing automotive parts, there are plenty of advantages, but some of the most notable ones in the industry include:
Faster Development
3D printing can be used as early as the prototyping stage to accelerate product development. Before 3D printing, prototyping could take weeks, if not months, due to the long turnaround times for molds and tooling. With 3D printing, product developers can easily print one-off prototypes in-house, evaluate them, and then implement changes in CAD software until the design meets all requirements and is validated.
This can be seen with Ford. In the last few decades, Ford has printed over 500,000 parts, which would have cost billions of dollars and millions of work hours to manufacture. A prototype that would have taken 4-5 months and $500,000 to produce using traditional methods can be produced as a 3D-printed model in days or hours for a few thousand dollars.
Design Flexibility
3D printing allows designers to iterate quickly due to its ability to produce prototypes directly from digital models. This process, known as rapid prototyping, lets designers experiment with different designs, materials, and structures in hours rather than weeks.
Each iteration can be quickly adjusted based on testing and feedback, enabling a more dynamic and responsive design process. The immediacy of 3D printing eliminates many traditional manufacturing constraints, empowering designers to push creative boundaries with greater speed and precision.
An example of this is Vins Motors, an Italian company that used 3D printing to develop the Duecinquanta, a performance motorbike with innovative design features, including a lightweight fiber chassis, that would have been challenging to create using conventional methods.
On-Demand Auto Parts
3D printing or additive manufacturing enables the production of custom, on-demand car parts by allowing car manufacturers, designers, and engineers to create 3D designs of the car parts needed, which can be directly printed using a 3D printer. This allows for rapid iteration, enabling the designers and engineers to test the product, gather feedback from the customer, and make necessary adjustments until it fits their specific needs.
3D printing reduces the need for a physical space to stock inventory as car parts can now be 3D printed when needed. But that’s not all. It also makes it easy to create custom parts for classic cars.
ABcar Oldtimers, a Polish car restoration service, used Zortrax Inkspire 3D printers to fabricate steering wheel components for a Ferrari 599 and dashboard elements for a vintage Mercedes Benz. They also employed M300 Plus and M200 3D printers to create custom parts for restoring a classic Porsche 911, significantly speeding up work and reducing costs compared to traditional manufacturing methods.
Cost Efficiency
Additive manufacturing focuses on producing only what is needed, effectively reducing waste and minimizing costs.
3D printing can also reduce manufacturing costs because–unlike traditional manufacturing methods–it doesn’t require expensive molds or dies, which can cost tens of thousands of dollars.
3D printing also enables manufacturers to test design variations at a cheaper cost with rapid prototyping. The process is also largely automated, which means cheaper labor costs per part produced–which can greatly impact the bottom line.
Applications of 3D Printing in the Automotive Industry
3D printing offers numerous possibilities for the automotive industry.
Prototyping
Over 70% of manufacturers are using 3D printing to create prototypes: early models or samples of a product printed to test design, functionality, and fit before full-scale production.
Prototyping used to be a very time-consuming process in the automotive industry taking weeks to create a physical model. But with 3D printing, prototypes can be done within hours, or even minutes depending on the size and complexity of the part. This speeds up product development (reducing overall production lead times) and can improve overall product design since multiple iterations can be done without significant added time or cost.
Designers and engineers can quickly create prototypes of components such as engine parts, transmission systems, dashboards, grilles, and interior fittings. This allows them to do multiple tests to see if the prototype meets all requirements, and in cases where it doesn’t, multiple iterations can be made until all requirements are met.
Custom Auto Parts
3D printing allows for the customization of parts, such as custom exhaust systems, bespoke interior trim pieces, personalized body panels, and specialized brackets or mounts tailored to individual customer preferences. This can also be used in seats for racing cars, key fobs, or gear sticks.
3D printing is flexible, meaning virtually any part of the car can be customized to exact specifications. This provides a level of personalization and performance optimization that traditional manufacturing methods struggle to achieve. You can even use it to create custom badges, emblems, or logos that reflect personal style.
Due to the COVID-19 virus, Seattle Children’s Hospital had to modify its shared shuttle program, which transports a significant percentage of its workforce to and from work. They quickly decided to install a protective barrier as a shield for the shuttle bus drivers and their riders–and brought in UPTIVE Advanced Manufacturing and Function Foundry to help.
UPTIVE saw an opportunity to utilize 3D printing to accelerate the process while also producing parts that were robust and aesthetically pleasing, while Function Foundry prototyped the design concept. UPTIVE was able to print and deliver custom parts with a shorter lead-time and at a lower cost than traditional channels–with the entire process from design to finished prototype taking approximately ten days.
Thanks to 3D printing, the process and approach allowed Function Foundry to offer a high-end solution for Seattle Children’s Hospital shuttles that blended form with function.
Tooling and Fixtures
In 2019, only 37% of manufacturers reported using additive manufacturing for tooling, but in 2021, that number grew to 57% in 2021. Why? While traditional methods require expensive tooling and can take weeks to produce a single jig, 3D-printed jigs and fixtures take less time and can be customized to fit specific car components. They can also be used to hold car parts in position during machining, drilling, assembly, or quality control testing.
Rosti Group, an injection molding company, has been able to produce assembly fixtures by using the UltiMaker S5Pro Bundle. The company has reduced lead times from one week to seven hours, and costs have been cut from $450 per part (while using more traditional CNC machining) to just $15 without compromising quality.
Learn how to set up custom work holding and tooling for your production floor.
Lightweight Car Parts
Car manufacturers are looking for ways to reduce the overall weight of their cars because a lighter car consumes less fuel and is more environmentally friendly. 3D printing makes it possible to produce lightweight structures that reduce a vehicle’s weight.
A German company, EDAG, used 3D printing to create a car called Light Cocoon. The car is extremely light, with only 19 grams per square meter.
Replacement Car Parts
3D printing can be used to replace car parts, especially in older, discontinued, or rare vehicles whose original parts may be difficult or near impossible to find. 3D printing allows manufacturers and repair shops to create replacements for the broken parts. This includes items like engine components, transmission housings, and even smaller parts such as knobs, switches, or brackets.
One manufacturer that has been doing this is Porsche. Porsche has been using 3D printing to create replacement parts for its classic vehicles. These include the clutch-release lever for the 959 and a crank arm for the 964.
How to 3D Print Car Parts
Here’s a step-by-step process of how to 3D print car parts.
1. Design Your Auto Parts
The printing process begins with designing the part to be manufactured. This is done using Computer-Aided Design (CAD) software, which provides a platform to create detailed 3D models or simulations of real-world products, complete with their specifications.
While CAD software is powerful, the design process can be time-consuming and requires precise measurements and a deep understanding of 3D modeling. It’s important to get this stage right—errors such as incorrect model orientation or other design mistakes can lead to failures in the entire manufacturing process.
2. Determine Your Materials
Choosing the right material for your 3D-printed part is important as it directly impacts the mechanical, physical, and chemical properties of the final car component, as well as the overall success of the 3D printing process.
In the automotive industry, some commonly used materials for 3D printing include:
- PLA: Polylactic acid is a plastic polymer made from natural, renewable plant sources such as cornstarch, sugar cane, sugar beet, or bamboo. It has good impact resistance, transparency, low melting point, good biodegradability, high strength, low thermal expansion, and good layer adhesion. It can be used to make interior car parts like dashboard components and upholstery
- ABS: Acrylonitrile Butadiene Styrene has high tensile strength, low melting point, and high rigidity, as well as resistance to impact, abrasion, and strain. These characteristics make it ideal for printing complex parts, and as a result, ABS can be used to make parts of the chassis and seat belt
- Metal: Metals such as aluminum, titanium, and steel are used in 3D printing due to their high strength, heat resistance, corrosion resistance, and ductility
- Carbon fiber reinforced plastics: Carbon fiber-reinforced polymers provide lightweight yet sturdy options, ideal for performance parts. These polymers are composite materials made from carbon fibers embedded in a polymer matrix that can be thermoset or thermoplastic. Carbon fiber-reinforced polymers are strong, stiff, and have an excellent strength-to-weight ratio to withstand high loads and stresses
3. Choose Your 3D Printer
The 3D printer you select will define your automotive and car parts’ quality, strength, and accuracy. Here are some factors to consider when choosing a 3D printer:
- Part size and complexity: If your car part is large, or requires specific intricate details, make sure the printer has the required build volume and precision
- Material compatibility: Consider the kind of material your printer can support if the specific part you need requires strength, heat tolerance, or flexibility
- Budget: Consider usage frequency when deciding whether to purchase one or not. If you will only be printing a few times a month, it may be cheaper to use a 3D printing service as you will have access to quality printers without having to purchase them
- Support and maintenance: Check the amount of support offered for your printer. Some printers are more complex and may need more attention, so decide whether you are willing to spend time on this
To take your production to the next level, work with a 3D printing service that can manage the entire process–delivering precision and speed while also solving your critical business challenges.
UPTIVE’s 3D printing services provide access to professional-grade printers and expert support, ensuring your car parts are made to the highest standards. These 3D printer options are all a great fit for 3D printing car parts:
- HP Multi Jet Fusion (MJF): Perfect for high-volume production, this printer provides design freedom and on-demand printing, eliminating the need to maintain large inventories. It allows for easy updates and revisions throughout the product life cycle, unlike the rigidity of injection molding.
- Stratasys and Markforged: Best suited for smaller quantities, these printers use advanced materials. Markforged offers flame-retardant composites that deliver metal-strength parts, while Stratasys provides aerospace-grade materials, with the F900 enabling the production of large parts in one unit.
Selecting the right 3D printer for your automotive and car parts production requires careful consideration of your specific needs, budget, and technical requirements to ensure optimal results and efficiency in your manufacturing process.
4. Print Your Car Parts
After securing your printer, the next step is to export the CAD file containing the model to your printer. Using slicing software, the printer slices the digital model of the structure to be printed into layers.
This process involves converting the 3D model into a series of 2D cross-sections and generating instructions called G-codes which the printer will use to build the structure layer by layer. The G-code is transferred to the printer, which follows the instructions and begins printing the structure.
5. Go Through Post-processing
3D-printed car parts typically require some post-processing before they’re ready for market release or final installation. Post-processing enhances both the appearance and functionality of these parts.
Here are some essential techniques:
- Cleaning: This process involves removing the support material, a temporary structure printed along with the 3D object to provide support for overhanging or unsupported areas. It also includes removing residual powder after selective laser sintering (SLS) or powder bed fusion (PBF) 3D printing and washing printed parts after stereolithography (SLA) processes.
- Fixing: This involves making small repairs on printed parts. It may involve filling unwanted holes with hardeners or gluing and welding small parts together.
- Curing: This involves curing or baking models after they have been printed to enhance their mechanical properties.
- Sanding and painting: Sanding smoothens the surface of the part, enhancing both its aesthetics and fit. Painting adds color and further improves the part’s appearance, giving it a finished look suitable for use or display.
It’s important to design your 3D-printed part with post-processing in mind. This means optimizing the design so that these operations—cleaning, fixing, curing, sanding, and painting—can be performed effectively and efficiently, ensuring the best possible final product.
Let’s explore some of the top 3D printing services that can help you achieve the best results.
Best 3D Printing Companies for Printing Car Parts
Here are the best 3D printing companies that offer advanced technology, high-quality materials, and expert knowledge to ensure your automotive parts are produced to the highest standards.
1. UPTIVE Advanced Manufacturing
UPTIVE Advanced Manufacturing is a leading provider of rapid manufacturing solutions that combines cutting-edge technology with personalized service. They’re challenging the rules of automotive parts manufacturing with a consultative approach that keeps production lines moving forward.
UPTIVE is built for manufacturers who demand precision, accuracy, and scalability. The company supports every stage of the production process, from prototypes to large-scale production runs, ensuring that each part is optimized for manufacturability and long-term success.
UPTIVE’s approach integrates advanced manufacturing techniques with a customer-centric focus, providing clients with:
- Expert guidance to ensure that parts are designed for manufacturability and scalability.
- Collaborative, long-term partnerships that foster continuous innovation.
- An extensive knowledge base to educate and support clients throughout the production journey.
UPTIVE focuses on the most important aspect of the product development process—personal service. In an industry full of automated quotes, limited personalization, and faceless transactions, UPTIVE provides customers with personalized support and guidance throughout the design and production process so customers get the best service imaginable.
3D printing services:
- Additive manufacturing
- Rapid prototyping
- CNC machining
- Sheet metal fabrication
- Injection tooling and molding
- Post-processing and finishing.
By combining the latest manufacturing technologies with personalized support, UPTIVE eliminates the complexities of rapid manufacturing, enabling clients to focus on what matters most—creating innovative, high-quality products that drive success in the automotive industry.
Getting started with UPTIVE is easy:
- Share your design file: Upload your design, and our experts will provide feedback on potential improvements for manufacturing.
- We inspect your design: Our engineering team will optimize your design for the chosen manufacturing process, ensuring feasibility and cost-effectiveness.
- Review and refine: We collaborate with you to refine the design and provide a quote that meets your specifications and budget.
Once you place your order, UPTIVE partners with you to bring your vision to life and ensure a smooth and successful production process.
Learn more about UPTIVE for 3D printing car parts
2. 3D Systems
3D Systems is an additive manufacturing company with hardware, software, and material solutions. The company offers 3D printers, printing materials, and on-demand manufacturing services.
Automotive manufacturers use 3D systems to create body exterior panels, metal structural components, and body interior and trim. The company also produces injection mold and die-cast tools.
3D printing services:
- Printer maintenance
- Visual and functional prototypes
- 3D printers, materials, and software
3. Additive Industries
Additive Industries offers automated and scalable metal additive manufacturing solutions. The company offers metal 3D printers such as the MetalFABG2 which are used in prototyping, tooling, spare parts, small series, or mass production vehicles.
Additive Industries also offers the Additive Studios program, which provides support with preparing designs and build files.
3D printing services:
- Additive Studios
- Metal Materials
- Prototyping & R&D
- Small series production
- Mass production
Make it Simple to 3D Print Automotive Parts
3D printing is changing the automotive industry by making the production of car parts faster, more flexible, and cost-effective. You can access incredible customization which allows for unprecedented creativity in the design process.
However, 3D printing car parts yourself is a huge lift–you’ll have to purchase a potentially expensive 3D printer, learn the advanced 3D printing technology and processes, know which materials to use…and much more.
Fortunately, with an end-to-end rapid manufacturing solution like UPTIVE Advanced Manufacturing, you can harness the power of 3D printing without the steep learning curve and upfront investment. UPTIVE provides customers with personalized support and guidance throughout the design and production process enabling the customer to get the best service imaginable. They’re focused on bringing the human touch back to an overly-automated industry.
Choosing UPTIVE means partnering with a company that understands the complexities of additive manufacturing and is dedicated to helping you achieve your goals efficiently and effectively. With their advanced technologies and experienced team, UPTIVE is well-equipped to support your journey into the future of manufacturing.