The Value of Additive Manufacturing in the Automotive Industry

Additive manufacturing is the process of making an object by building it one layer at a time. It is an alternative to subtractive manufacturing, which creates objects by cutting pieces off a solid block of material. The term covers many technologies, including 3D printing, fused deposition modeling (FDM), and selective laser sintering (SLS). It has become a major trend in the automotive industry recently.

1. Weight Reduction

Weight reduction in vehicles is the most efficient way to increase fuel economy. Studies have found that reducing a vehicle's weight by approximately 10% can increase mileage by 6 to 8%. Additive manufacturing builds each component from thin layer to thin layer, making it easier to create hollow pieces and use lighter materials. This is especially valuable for electric vehicles that require weight reduction to improve battery life between charges.

2. Manufacturing Replacement Parts

3D printers can facilitate vehicle maintenance and repairs. Automotive experts can create replacement parts using the technology, meaning there is no need to stock spares. A SmarTech Analysis report found that automotive 3D printing will have generated $9 billion in revenue from the production of end-use parts alone by 2029, paving the way for increased servicing speeds and lower maintenance costs.

3. Rapid Prototyping During R&D

The automotive industry is ever-changing, with electric vehicles and self-driving cars being the latest developments. Automotive manufacturers need to continually perform research and develop new technologies to remain competitive. Additive manufacturing allows brands to create working prototypes in record time, so product designers can test and iterate inventions in a cost-effective manner.

4. Streamlining Customization

Volkswagen has been using additive manufacturing technologies over the past 25 years, citing that 3D printing allows the brand to further optimize the design process. Additive manufacturing makes it easier to create customizable vehicle parts cost-effectively, because parts do not need machinery or molding techniques that require extensive capital and personnel, making vehicle features more compliant with consumer demands.