REINVENTING GO-TO-MARKET
3D printing is revving up auto manufacturing
by Christoph Schell , President , Americas , HP
Self-driving cars are set to transform the automotive industry . But major changes are already taking place in automotive manufacturing thanks to 3D printing . Additive manufacturing ( AM ) is paving the way for new car designs , lower costs , and shorter production times . In a scenario offered by 3DPrint . com , using 3D printing , consumers would be able to order a car online , which could be designed to their own specifications , and have it shipped in less than two days . While the industry isn ’ t ready yet to offer on-demand cars , it is already showcasing next-generation models based on AM . Notable among them is a functional 3D-printed model of the class Shelby Cobra sports car , made up of 20 percent carbon fiber and 80 percent thermoplastic resin . Printed at the Department of Energy ’ s Manufacturing Facility at Oak Ridge National Laboratory , an estimated 75 percent of the vehicle ’ s parts are produced by AM .
Additive manufacturing offers a promise of a range of new vehicles for public transport as well . Last year , Arizona automaker Local Motor debuted Olli , a crowdsourced primarily 3D-printed , self-driving electric shuttle bus outside Washington , D . C .. This year , Deutsche Bahn , the German railway company plans to begin testing Olli under a pilot project in Berlin .
The Shelby Cobra and Olli provide a glimpse into what ’ s coming down the road in 3D printed car and vehicle fleet design . However , there are several current applications for 3D printing in the automotive industry today . In its recent report on “ Additive Manufacturing Opportunities in Automotive — 2016 ,” SmarTech Publishing estimates the 3D printing automotive market will reach $ 2.3 billion in 2021 from its current $ 600 million .
Rapid prototyping
For some years now , rapid prototyping has been helping automotive manufacturers to cut down lead times for designing new cars or updating current models . The use of 3D manufacturing means auto manufacturers can test a variety of prototypes before production . Ford Motor Company says that prototype parts can be built in days or hours , versus months , at far less cost than using traditional methods since 3D printing eliminates the need for tooling and molds .
Parts production
The use of metal as a printing material is still in its early stages . Audi , as one example , is using 3D printing to produce the metal water pump wheel of its DTM race car , which replaces a previously plastic part . The German car manufacturer is also using the technology to produce spare parts and in turn , disrupt the supply chain .
The current method of dealers ordering parts from a central location is costly and time consuming . Besides benefiting the customer , the process is eliminating the over production of certain parts .
Continuous parts improvement
The use of 3D printing in the automotive industry doesn ’ t begin and end with the printed part . As manufacturers embed tracing marks and sensors into the product , they will be able to track every step of a product lifecycle from initial 3D object scan to design through production , quality measurement , delivery , and real-world use . Using in-lifecycle information , manufacturers can improve the design and fabrication of future parts .
The use of 3D printing for automotive manufacturing is leading to new levels of innovation . With its potential for customization and convenience , 3D printing will put consumers in the driver ’ s seat . •
Christoph Schell is President of the Americas Region for HP . In this role , Christoph is responsible for the go-tomarket strategy and overall financial performance of the Americas business products and services across all markets .
Issue 7 · Summer 2017 · Innovation Journal 15