E-MOBILITY
to start, would have caused shutting down the assembly line and delaying the introduction of this SUV into the market. Instead, the first 30,000 vehicles were equipped with the 3D-printed version of this seal, until the injected version arrived to continue production. This is what we call bridge production, and it saved GM a huge cost.
INCREASED CUSTOMER SUCCESS THROUGH INCREASED FREEDOM OF CHOICE We are in the era of customisation, where consumers expect to choose more and more aspects of their new car. However, this comes at a cost, as fragmentation of demand goes against economies of scale when using injection moulding—especially when a high upfront investment in tooling is required. Instead, in additive manufacturing there is no tooling, which enables greater freedom of choice to consumers at no significant additional cost. For example, Stellantis recently launched the new Peugeot 308. It comes with 3D-printed interior accessories available in multiple
colours and shapes to delight its customers. Similarly, other well-known
automotive brands are introducing limited editions, with exclusive designs, that become more economically viable thanks to additive manufacturing. This is possible with technologies like HP Multi Jet Fusion and HP Metal Jet, which deliver end- user parts that resemble injected parts and hence, meet consumers’ high expectations.
COST SAVINGS IN THE ASSEMBLY LINE Manufacturing is an essential element in vehicle cost. Optimising the speed at which cars are assembled, while increasing the ergonomics of workers, and reducing human error, can have a direct impact in the overall manufacturing P&L. In this context, car factories are adopting additive manufacturing to source and improve their jigs and fixtures and, even more, 3D-printed spare parts for their machinery. Recently, a Ford factory in Valencia, Spain, reported that more than 20,000 parts were produced in just one year, mostly with HP Multi Jet
Additive manufacturing enables complex, organic shapes that cannot be achieved with injection moulding
Fusion technology. In conclusion, the automotive
industry is using additive manufacturing to bring increased performance to essential EV systems, enable higher customisation to their customers, and save costs in manufacturing through bridge production and improved jigs and fixtures.
Xavier Llobera is Automotive Segment WW Manager at HP 3D Printing & Digital Manufacturing
Additive manufacturing allows greater customisation of automotive parts
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