3D printing has evolved from a niche prototyping tool into an essential pillar of the automotive industry. Today, its application is shifting from simple modeling to the production of end-use components, with leading automotive brands leveraging the technology to cement their dominance in the sector. In this feature, the 3D printing technology reference examines how major global automakers are integrating additive manufacturing (AM) into their mainstream operations.

Daimler Group

The German automotive giant—home to brands like Mercedes-Benz, Smart, and Maybach has long utilized additive manufacturing for diverse component production. Since 2017, Daimler has partnered with EOS and other industry leaders on the NextGenAM project, which aims to establish standardized, large-scale production lines using metallic Powder Bed Fusion (PBF) technology. While the NextGenAM platform is already producing specific truck components, its potential for passenger cars and electric vehicles (EVs) is currently being evaluated.

In the commercial vehicle sector, Daimler has fully integrated AM into product development and series production. Through group-wide research, the company has successfully accelerated the implementation of 3D printing for Daimler Trucks and Buses. Furthermore, the group is focusing on digitalizing spare parts and inventory, moving toward a print-on-demand model for legacy components.

Highlight: Mercedes-Benz uses metal 3D printing for spark plug holders in the classic 198-model series toolkits.

In the realm of high performance, Mercedes has utilized metal 3D printing in its highly successful Formula 1 cars for over a decade. While Daimler buses primarily use polymer Selective Laser Sintering (SLS), the Mercedes-Benz Classic 3D division provides essential replacement parts for vintage icons like the 300 SL.

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BMW Group

BMW’s adoption of AM accelerated significantly in 2016. The group operates a dedicated Additive Manufacturing Center in Munich and recently opened a new €15 million Additive Manufacturing Campus this past June. BMW’s ecosystem includes partnerships with 3D Systems’ advanced center in Italy and investments in key tech players like Carbon and Desktop Metal.

BMW holds the distinction of being the first automaker to massively produce metal parts by the thousands. A prime example is the soft-top fixture for the BMW i8 Roadster, manufactured using aluminum alloy Selective Laser Melting (SLM). By 2018, BMW had produced over one million 3D-printed parts over ten years, notably, 200,000 of those were made in 2018 alone, representing a 42% year-over-year increase.

The MINI brand has also embraced polymer powder bed fusion via the MINI Yours Customised program, allowing customers to design their own components. Meanwhile, luxury brand Rolls-Royce utilizes 3D printed parts in its flagship Phantom and Dawn models.

Volkswagen Group

Volkswagen is one of the most proactive proponents of AM, striving to push the technology toward high-volume manufacturing. At its advanced 3D printing center in Wolfsburg, VW tests the latest hardware for both tooling and end-use parts. For massive production runs, the group often collaborates with external service providers.

The group’s high-end brands are also leading the charge:

  • Audi has used SLM Solutions equipment for years to produce spare and series parts.
  • Porsche: Invested in Markforged in 2017 to create parts for classic models like the Porsche 959.
  • Bugatti collaborates with SLM Solutions for series production and works with APWORKS to design components for the Chiron.
  • Lamborghini, a long-time user of FDM and PolyJet for rapid prototyping, Lamborghini partnered with Carbon in 2019 to utilize Digital Light Synthesis (DLS). Initially used for textured fuel caps and air duct clips on the Urus SUV, the tech now produces customizable air vents for the Sián FKP 37 hybrid super sports car, slashing lead times by 12 weeks.

Fiat Chrysler Automobiles (FCA)

FCA (now part of Stellantis) was a pioneer of 3D printing in Italy, starting with prototyping at its Turin plant. Today, Jeep and Fiat utilize HP Multi Jet Fusion (MJF) for series production. Jeep, for instance, runs an average of 4 to 5 print batches per week.

Luxury brand Ferrari applies AM in its Formula 1 operations, while Alfa Romeo uses it to develop and produce the grille for the Giulia. In 2019, following the merger with the PSA Group, there has been a significant push toward metal 3D printing through a partnership with Divergent 3D. Divergent’s “Blade” supercar features a chassis almost entirely 3D-printed. Using SLM Solutions’ technology, they plan to begin mass-producing safety-critical structures for OEM customers starting in 2020.

Ford Motor Company

Ford has arguably conducted more research into the industrialization of AM than any other automaker. Its Advanced Manufacturing Center in Redford, Detroit, houses dozens of industrial 3D printers from Stratasys, HP, Carbon, EOS, and more.

Ford uses Carbon’s DLS technology for end-use parts, such as HVAC lever arms for the Focus, auxiliary plugs for the F-150 Raptor, and electric parking brake brackets for the Mustang GT500. Globally, Ford operates nearly 100 printers across 30 plants. Following a $65 million investment in Desktop Metal, Ford became an early adopter of their Studio and Production systems. Additionally, Ford works with Stratasys and Siemens on multi-axis extrusion systems to produce oversized composite parts.

General Motors (GM)

GM was an early adopter, using industrial SLA and FDM for over a decade. Its AM research is centralized at the Warren Tech Center in Michigan, which produces over 30,000 parts annually.

In 2018, GM collaborated with Autodesk to produce a 3D printed stainless steel seat bracket. The resulting part was 40% lighter and 20% stronger than the original. GM estimates that up to 100 components could eventually be produced via cost-effective AM processes.

GM is currently working with GKN to use HP Metal Jet for mass production and is collaborating with GE Additive and Italian service provider Beam-IT on industrializing metal PBF. Looking to the future, GM and Michelin are exploring 3D printing to create the Uptis airless tire, aiming for a 100% recyclable product.

Additive manufacturing has met the rigorous demands of the automotive industry, driving a revolution in design. Today, 3D printing is capable of producing end-use parts in both metal and plastic, making mass manufacturing a reality. As technology matures and expertise grows, the focus is shifting toward deeper and faster integration into the standard production assembly line. For AM companies, that remains the ultimate finish line.