The Role of AM in the Automotive Industry

In the automotive industry, OEMs have historically mostly used additive manufacturing for rapid prototyping. In more recent years however, advances in AM have slowly been transforming the ways in which end-use parts are designed, manufactured and distributed. Deloitte’s 3D opportunity in the automotive industry study explains that in the current standard AM path, companies do not seek radical alterations in either supply chains or products. AM is adopted to create design iterations, to enhance quality through cost-effective prototyping, and to create specific tooling parts. Nevertheless, other AM paths in automotive exist, which transform products and supply chains more radically. This is what we will explore in the following overview of additive’s impact in the automotive industry. In fact, SmarTech Analysis’ report revealed that by 2029, automotive 3D printing will have generated $9 billion in revenue from the production of end-use parts alone, compared to $1.39 billion in 2019. So, where is AM in this sector headed?

Pre-production benefits

Accelerating the product design phase during new product development is key in any industry. Thankfully, 3D printing can replace expensive and long lead-time CNC production in this phase. More precisely, it enables designers to cost-effectively go through several iterations before deciding on the final product. The process is as follows: once designers have identified a user need and have generated ideas to meet that need, they develop a prototype. The next stage is to test this prototype in order to improve its design. This iterative process is also what we call rapid prototyping.

Sample metal 3D printed water connectors for the Audi W12 engine | Photo Credits: Volkswagen AG

Volkswagen, for example, has been working with 3D printing technologies for the past 25 years. And in 2020, it invested in two additional Stratasys 3D printers. Peter Bartels, head of Volkswagen’s pre-series centre commented that these investments represent “additional capabilities that strengthen 3D printing operations and allow to further optimize the design process.” Additionally, tooling (grips, jigs, and fixtures) design can also be optimized and produced at a lower cost. Tooling plays an important role on the assembly line to produce repeatable and high-quality products. These applications are what Deloitte calls the current standard AM path in automotive.