Divergent Secures $160M to Revolutionize Automotive Manufacturing with Additive Manufacturing and DAPS

Divergent, a trailblazer in advanced manufacturing, recently announced a significant achievement, successfully raising $160 million in funding. This substantial investment is earmarked to propel the company’s ambitious mission: to dramatically reshape the automotive industry by leveraging additive manufacturing for producing intricate car parts. At the core of Divergent’s innovative approach is the Divergent Adaptive Production System (DAPS^®), a sophisticated software solution coupled with an automated assembly system. This proprietary system is engineered to design and optimize nearly every component of a vehicle, from chassis to complex structural elements. To bring these designs to life, Divergent has strategically partnered with SLM Solutions, deploying their state-of-the-art NXG XII 600 metal 3D printer. The newly acquired funds are critical to scaling up Divergent’s manufacturing capacity, with plans to establish new production facilities across the United States and Europe beginning in 2024. This expansion marks a pivotal step in making their cutting-edge digital manufacturing processes more accessible to global automotive original equipment manufacturers (OEMs).

For many enthusiasts of advanced manufacturing and automotive innovation, the name Divergent resonates deeply. The company first captured global attention in 2015 when the California-based startup unveiled “Blade,” a groundbreaking concept car that showcased the immense potential of 3D printing in vehicle construction. The Blade featured an ultra-lightweight chassis, ingeniously designed using carbon fiber tubing held together by intricate 3D printed aluminum fasteners. This demonstration was not just a proof of concept; it was a powerful statement on how additive manufacturing could drastically reduce vehicle weight, improve performance, and enhance fuel efficiency. Following this impactful debut, Divergent forged a strategic partnership with the automotive giant Peugeot, a collaboration that further validated its innovative vision and helped secure its initial round of funding. Since those early days, Divergent has been diligently working behind the scenes, continuously refining its technology and setting even more ambitious objectives, moving beyond concept vehicles to comprehensive production systems.

Divergent has consistently explored 3D printing for automotive chassis production for several years (photo credits: Divergent)

While Divergent may have maintained a relatively low profile in recent years, their dedicated efforts have been focused on perfecting their comprehensive solution for developing custom automotive parts. This solution seamlessly integrates advanced generative design methodologies with state-of-the-art additive manufacturing processes. Divergent’s proprietary end-to-end system is envisioned as a complete, modular digital factory, specifically tailored for the production of complex structures. The profound innovation embodied by DAPS is safeguarded by an impressive portfolio of over 500 patents, underscoring its unique technological foundation. The intelligent software at the heart of DAPS is capable of analyzing a component’s intended volume, its precise attachment points within the car, and the specific structural loads it must withstand throughout its operational life. Based on these critical constraints, the software autonomously optimizes the part’s weight, strength, and manufacturing cost. This iterative design process ensures that each component is not only exceptionally robust but also as lightweight and cost-effective as possible before it proceeds to the 3D printing phase. For precision and speed, Divergent has standardized on laser powder bed fusion technology, deploying six of SLM Solutions’ high-performance NXG XII 600 3D printers, known for their ability to produce large, complex metal parts with exceptional detail and speed.

The innovation extends beyond manufacturing to the assembly process itself. Once a part is precisely 3D printed and verified, it is moved to an autonomous assembly system, significantly reducing both manufacturing time and the need for human intervention. This streamlined workflow dramatically boosts efficiency and consistency, minimizing potential errors. Lukas Czinger, Divergent’s Senior Vice President, elaborates on the transformative power of DAPS, stating, “DAPS creates radically more efficient structures using a fraction of the typical engineering time and transforms automotive companies from CapEx-constrained businesses to flexible, design-driven organizations. It is the first instance of digital industrial manufacturing. The factory infrastructure stays consistent regardless of the design, only the data changes, allowing DAPS to switch between differentiated designs seamlessly with no downtime in-between. DAPS entering serial production this year represents a historic inflection point in automotive manufacturing.” This emphasizes a fundamental shift in how vehicles are produced, moving away from rigid, capital-intensive assembly lines towards agile, data-driven digital factories capable of mass customization and rapid design iteration without significant retooling or delays. The ability to seamlessly switch between different vehicle designs or components without downtime provides an unparalleled level of flexibility and responsiveness to market demands, a paradigm shift for traditional automotive production.

Divergent’s strategic objective is to deliver a comprehensive, turnkey solution capable of designing and producing nearly the entire vehicle (photo credits: Divergent)

Initially, Divergent is strategically focusing its pioneering efforts on the sports car and high-end vehicle segments. This approach is rooted in the economic attractiveness of these markets, where higher margins and a greater willingness to adopt cutting-edge technologies make them ideal proving grounds for DAPS before its potential expansion into mainstream vehicle production. Kevin Czinger, the visionary founder and CEO of Divergent, articulates the profound impact of their recent funding, stating, “This funding represents a sterling affirmation of how disruptive we are in the auto manufacturing industry, one that really hasn’t experienced such revolution since Henry Ford developed the assembly line more than 100 years ago. Of great importance, given the global focus on sustainability, DAPS is planet-saving manufacturing in that it radically reduces lifecycle environmental impact by optimizing total vehicle ‘cradle-to-cradle’ efficiency.” This bold comparison to Henry Ford’s assembly line underscores Divergent’s belief that DAPS represents a fundamental paradigm shift, moving beyond incremental improvements to a truly revolutionary approach. The “planet-saving” aspect is particularly compelling in today’s climate-conscious world. DAPS achieves radical environmental benefits by minimizing material usage through lightweighting and generative design, drastically reducing waste in the production process, and ultimately contributing to more energy-efficient vehicles throughout their entire lifecycle. The “cradle-to-cradle” efficiency means considering the environmental impact from raw material extraction to end-of-life recycling, ensuring a circular economy approach. Divergent further revealed that the DAPS solution is currently being utilized by eight undisclosed automakers, with their identities expected to be unveiled later this year—a testament to the system’s robust capabilities and market acceptance. For more in-depth information about Divergent’s innovative technologies and strategic vision, you can explore their official website HERE.

The successful fundraising by Divergent and the imminent expansion of its DAPS technology signify a transformative moment for the automotive industry. It heralds an era where vehicle design and production are no longer constrained by traditional limitations but are instead driven by digital innovation, sustainability, and unprecedented manufacturing flexibility. We are eager to hear your thoughts on this significant development and its potential implications for the future of car manufacturing. Please share your insights in a comment below or join the conversation on our LinkedIn, Facebook, and Twitter pages! For the latest updates and breaking news in the world of 3D printing, remember to sign up for our free weekly Newsletter here, delivered straight to your inbox! Additionally, you can discover all our engaging video content on our dedicated YouTube channel.