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Innovate or Lose the Race: The Future of Automotive Manufacturing

Matt Hitch
Matt Hitch August 26, 2024
August 26, 2024
Concept Modeling Prototype for VW | Stratasys Direct

The Future of Automotive Manufacturing

The automotive industry is a high-speed race where innovation is the ultimate fuel. Once trailblazers, automakers now face unprecedented challenges: rising material costs, supply chain disruptions, and the relentless demand for higher performance, lighter weight, and electrified vehicles. To stay ahead, manufacturers must fundamentally transform their production processes. Additive Manufacturing (AM), or 3D printing, offers a powerful solution. 

The AM Advantage for Automotive

Stratasys Direct is at the forefront of leveraging AM to revolutionize the automotive industry. By offering unparalleled design freedom, rapid prototyping, and production efficiency, we empower automakers to overcome challenges and seize new opportunities. 

  • Design Freedom and Optimization: AM, with its ability to create intricate geometries, unlocks innovative designs that were once impossible. Our expertise in advanced materials and complex part production enables automakers to push the boundaries of design, resulting in lighter, stronger, and more efficient components. 
  • Rapid Prototyping and Iteration: Time-to-market is critical in today's competitive landscape. Stratasys Direct's rapid prototyping capabilities accelerate the design-to-production cycle, enabling automakers to quickly iterate and refine designs, reducing development costs and time-to-market. 
  • Production Efficiency and Cost Reduction: Traditional manufacturing methods often involve high tooling costs and lead times. AM, with its ability to produce parts on-demand, can significantly reduce production costs and inventory requirements. Our expertise in scaling AM for production ensures a smooth transition from prototyping to low-volume manufacturing. 
  • Customization and Personalization: Consumers demand vehicles tailored to their specific needs and preferences. AM offers unprecedented customization opportunities, allowing automakers to create highly personalized vehicles. Our ability to produce complex, customized parts at scale enables mass personalization without compromising efficiency. 
  • Accessories and Aftermarket: The automotive aftermarket is a dynamic and growing market. AM is transforming this space by enabling rapid production of customized accessories and performance parts. From functional upgrades to aesthetic enhancements, Stratasys Direct empowers businesses to capitalize on this opportunity by delivering high-quality, on-demand parts that meet the evolving needs of consumers. 
Rousch Camera Mount | Stratasys Direct

Real-World Applications with Stratasys Direct

Stratasys Direct is already partnering with automotive manufacturers to deliver tangible results: 

Case Study 1: Volkswagen used 3D printing to create complex multi-material PolyJet prototypes that mirror final production parts up to 99% precision. This reduced the product development cycle by 2 months with full design freedom 

Case Study 2: Manufacturing Tools -- Ford replaced a quarter glass alignment fixture with new FDM 3D printed tool that was more ergonomic and lightweight. Weight reduction of 15% and 70% cost savings compared to traditional manufacturing 

Case Study 3: Spare Parts -- Porsche has used 3D printing to fabricate on-demand customized spare parts, such as clutch release levers, using selective laser melting via additive manufacturing. 

Case Study 4: End Use Production -- Roush Performance utilized SAF technology to 3D print a grill camera mount design change late in the production cycle, reducing the cost by 94% and saving 4 months of time. 

Shaping the Future with Stratasys Direct

To fully realize the potential of AM in automotive manufacturing, innovation is essential, as is working with a knowledgeable and trusted service provider. Stratasys Direct has a proven track record of delivering tailored AM solutions for leading automakers.  

Our extensive material portfolio, including high-performance options like Nylon 12CFR, PA11, PA12, and the newly added SAF Polypropylene, combined with our PPAP expertise, positions us as a strategic partner for the automotive industry. By choosing Stratasys Direct, automakers gain a competitive edge, accelerate innovation, and drive product development forward. 

3D Printed Automotive LED Lighting on a Land Rover | Stratasys Direct

Bridging the Gap to AM Adoption 

Many automotive companies embrace AM and recognize its potential, but still face barriers to full-scale implementation. Stratasys Direct offers a seamless on-ramp. Our extensive AM expertise, combined with our strategic partnership with our parent company Stratasys, provides a flexible solution. Whether you need rapid prototyping, low-volume production, or simply want to explore AM's possibilities, we can bridge the gap between your vision and reality without the upfront capital investment. 

Let's build the future of automotive manufacturing together.