By Fadi Abro, Global Automotive Director, Stratasys
The automotive industry is accelerating to net zero, but there are more than a few bumps in the road. Despite publicly stated ambitions to reach that milestone by 2050, the OEMs and their suppliers must oversee a radical shift in manufacturing operations to reduce emissions from every aspect of the production process.
That challenge was highlighted in a recent report from consultancy BDO on the UK automotive sector. The ‘Getting Ready for a Net Zero Future’ study revealed a high awareness of environmental responsibilities, with 93% of respondents believing the transition to net zero would be important for them in the long term. However, the report was laced with a tone of realism, with the respondents consistently noting the significant challenge ahead.
This sentiment is felt similarly across the rest of the European automotive industry. And yet, there is hope. The BDO report indicated a strong willingness to embrace and adopt new technologies en route to net zero. When questioned about where business investments would be focused for net zero initiatives, almost half said greater digital transformation. Meanwhile, nearly a third of companies cited adopting green capital equipment and production. New manufacturing processes are clearly critical to greener automotive operations.
How additive manufacturing can deliver sustainability advantage
But what does that mean in reality? Which production-ready technologies can be deployed today to support the shift to net zero? Step forward additive manufacturing (AM). This transformative technology is finding increasing application among OEMs and the supply chain both as a prototyping and production tool as companies look to overcome challenges such as the rising cost of materials and design restrictions from traditional subtractive parts production. The fact that AM also delivers multiple sustainability advantages makes it a compelling option.
So, let’s look at those sustainability advantages in greater detail. They include:
1. Manufacture closer to the point of consumption
Car manufacturers are well aware of the enormous carbon footprint of shipping parts by air or sea from halfway around the globe. By producing components closer to where they are needed, AM cuts down on those long-haul journeys and their considerable environmental footprint. The decentralised nature of AM enables localized production, producing automotive parts closer to production lines
2. Ability to produce complex designs using fewer resources
With AM, engineers and designers can create more intricate geometries and lightweight structures and consolidate them with innovative patterns that optimize performance and minimise waste. This approach translates to fewer resources consumed in parts production and fewer overall emissions. Unlike traditional manufacturing, AM can cut down on waste and materials costs by up to 90%, producing items on demand with no moulds or excess waste. Decarbonising operations through AM requires time and resources for proper measurement, reporting, and continuous improvement, but it is worth the effort as it offers efficiencies that traditional manufacturing methods, such as milling, simply cannot.
3. Lighter and more consolidation parts for increased efficiency
Car manufacturers and suppliers can use AM to produce lighter, stronger components that improve fuel efficiency and reduce emissions. Lighter components equals greater range, and this is a critical consideration for the more widespread adoption of electric vehicles. Furthermore, the design flexibility afforded by AM allows for consolidating multiple parts into single, complex structures, thereby enhancing overall vehicle performance.
4. Smaller inventories and reduced deliveries to site
AM aligns with circular economy principles by reducing the need for inventory overstock. Traditional manufacturing often requires the production of surplus parts to account for potential demand, leading to overproduction and waste. In contrast, AM enables a ‘just-in-time’ production model, where parts are produced as required, thus minimising excess stock and aligning with the reuse, redesign, repurpose, and recycling ethos of the circular economy. Additionally, using more sustainable materials in AM, such as bio-based thermoplastics, further bolsters the technology’s environmental credentials.
AM finds increasing application across automotive
That’s the sustainability case for AM in automotive. Other benefits are emerging – particularly around overcoming challenges of economies of scale associated with low-volume production that takes place with special editions and personalisation. Consumers are increasingly demanding vehicles tailored to their specific needs and preferences. AM allows automakers to produce customised parts, enabling personalisation without compromising efficiency.
Meanwhile, the automotive aftermarket has emerged as a dynamic and growing market. AM is transforming this space by enabling the rapid production of customised accessories and performance parts. From functional upgrades to aesthetic enhancements, this can provide a valuable means of differentiation in automotive.
With these factors in mind, it is no surprise that the AM market is growing at pace. A recent report states it will be worth an estimated $13.75 bn by 2028. Indeed, Stratasys is already partnering extensively with some of the most prominent automotive manufacturers in the world to deliver tangible results, from prototyping right through to production.
For example, Volkswagen has used 3D printing machines to create complex multi-material PolyJet prototypes that mirror final production parts with up to 99% precision. This reduced the product development cycle by two months with full design freedom. Meanwhile, Ford replaced a quarter glass alignment fixture with a new fused deposition modelling (FDM) printed tool that was more ergonomic and lightweight. This approach meant weight savings of more than 15% and cost savings of 70% were achieved compared to traditional manufacturing.
Porsche has also used AM to fabricate on-demand customised spare parts, such as clutch release levers, using selective laser melting. Finally, racing firm Roush Performance has deployed Selective Absorption Fusion technology to print a grill camera mount design change late in the production cycle, reducing the cost by 94% and saving four months of time.
Securing a more sustainable future
In conclusion, the automotive industry has recognised that AM can help it navigate the journey to net zero through design flexibility, localised production, material efficiency, reduced energy consumption, and using repurposed, reused, and recycled sustainable materials. It is also opening up new use cases and streams of revenue through emerging approaches such as personalisation and customisation.
In short, AM is a genuine enabler of automotive innovation – delivering environmental and operational advantages that support a more sustainable tomorrow.
