by Cassandra Balentine
Three-dimensional (3D) printing plays a growing role in automobile manufacturing, from prototypes to end use parts production.
Shown: A miniature model broken into components for inspection. All objects were printed on the
Mimaki 3DUJ-553 3D printer.
“Automobile manufacturers were among the first companies to adopt 3D printing. They have a long history of accelerating product development of using it for part and assembly prototyping, design models, and various tooling applications,” comments Dave Flynn, business line manager production, Materialise.
Many materials support the production of 3D printed parts, including plastic-based options.
Plastic-Based 3D Printing
Matthew Stark, 3D segment manager, Mimaki USA, Inc., points to jigs, fixtures, and out-of-production part manufacturing through digital warehousing and mockups as popular applications created with plastic 3D printing materials.
Jon Walker, government relations and key account manager, EOS, sees it mainly used for prototyping or preproduction needs. “Selective laser sintering’s (SLS’) unique ability to match injection molding parts most closely, compared to any other 3D technology, enables the most options when it comes to prototyping large or missing critical parts, like instrument panels. There are some end use production parts for electrical connections, vehicle customization, and spare parts.”
Fused filament fabrication (FFF) machines are mainly used to facilitate easy production of parts that would otherwise require expensive tooling—injection molding—or much more expensive outsourced machining—CNC machining. “This results in less overhead and fewer man hours working on these parts as the workflow is cut down significantly. A typical workflow looks like this—designing the 3D model in a CAD software, exporting the 3D model, slicing the model in a 3D printer job preparation software—also known as a slicer, then printing,” says Christopher Thibeault, service engineer, BigRep America Inc.
Along with manufacturing operations, Thibeault says fused deposition modeling (FDM) machines also optimize the workflow for creative aftermarket automotive parts and restoration projects by making one-off parts. Like in manufacturing, the time and costs associated are significantly less for businesses when compared to traditional methods of fabrication.
Through its software solutions, Materialise works with major automotive manufacturers. From this perspective, Flynn says the four primary use cases for plastics in 3D printing in automotive are prototyping for rapid iteration; custom tooling and fixtures; low-volume customization; and increasingly, end use parts production.
Next-Gen Manufacturing
Custom jigs and fixtures mean faster manufacturing turnaround. “3D printing parts from a digital warehouse allows companies to service vehicles that are no longer in production. 3D printed mockups speed up the design process,” explains Stark.
Thibeault adds that 3D printing can decrease lead times for custom parts, assembly jigs, fixtures, and in some cases even tooling, while also providing capabilities for manufacturing many parts on site that would previously be outsourced.
Flynn agrees, noting that speed and agility are offered with 3D printing. “Our customers can make faster decisions, reduce supplier dependency, and increase production flexibility. But the real game-changer is digital control. This isn’t just about printing parts; it’s about transforming how automotive manufacturers manage their entire additive manufacturing (AM) operations.”
Thibeault points out that 3D printing gives more flexibility for part design that was once impossible with the limitations of injection molding or CNC machining.
Further, robots have entered the picture. Walker admits that it’s not a “new” idea to 3D print the end effector for a robot, but it is having a moment. “People are hitting the limitations of FDM in this space and the unique abilities of SLS are crafting those parts that other technologies cannot do.”
Industry Advancements
Advancements in the plastic-based 3D print space for automotive include new materials, better material recyclability, and the newer machines launching that are much cleaner to operate and run, suggests Walker.
Stark sees lower prices, more engineering-grade materials, and faster printing speeds.
In recent years, Thibeault notes large strides in the general productivity of FFF machines. “Features previously reserved for hobbyist or ‘prosumer’ class 3D printers are now adopted by industrial machines to a much higher extent as this industry matures.”
Advancements also include multi-material systems like BigRep’s VIIO 250 with an Infinity Box, an automated filament handler feature similar to options available in popular desktop 3D printers. “Auto calibration—i.e. probe Z-offset calibration, input shaping, encoder-based flow calibration, and clog detection—greatly decreases the amount of time a machine operator needs to spend with the machine before getting a print job running,” says Thibeault.
“This, in my opinion, has made adoption much easier for companies as the quick turnarounds and deadlines in the automotive industry make budgeting for a dedicated machine operator difficult to justify to leadership,” explains Thibeault.
Flynn says Materialise’s software has driven several key advances including seamless integration with enterprise systems through its CO-AM Software Platform, automated workflows that reduce human intervention, real-time monitoring and quality control, and scalability solutions that enable manufacturers to move from prototyping to production volumes. “We essentially digitized and industrialized 3D printing for automotive applications.”
Which Parts
A variety of plastic parts are printed in 3D for automotive use, including jigs and fixtures in addition to trim and exterior components.
However, Stark points out that 3D printing is slow and not made for mass manufacturing. “Typically short-run parts or parts that cannot be manufactured traditionally are being 3D printed. There are also limitations on material properties in 3D printed plastics so there are many components that are still unable to be 3D printed due to lack of strength or chemical resistance.”
Any part where tooling costs cannot be justified by the volume—such as low-volume, customized pieces or niche, geographical market variants, are well suited for 3D printing with plastics, says Walker.
Additionally, Walker suggests that any part too sophisticated to print or requires design for AM and cannot be molded, is a good candidate.
Flynn says Materialise’s software enables 3D printing of everything from complex interior components and lightweight structural parts to custom tooling and fixtures. “The ‘why’ is often geometric complexity, customization needs, or rapid iteration requirements, all scenarios where our software optimization really shines. Our RapidFit+ subsidiary specializes in high-precision tooling where traditional manufacturing would be cost prohibitive or time consuming,” comments Flynn.
In automotive manufacturing, Thibeault says FFF 3D printing is commonly used for rapid prototyping along with jigs and fixtures to support their manufacturing operations. “When we extend this to automotive aftermarket, use cases become much more diverse. This is where the ease of rapid prototyping with FFF really shines. Between our machine and print service customers we see an assortment, from full-scale bumpers, fenders, interior panels, subwoofer enclosures, speaker grills, and aerodynamic components. These can now be printed rather than machined or made with fiberglass molds, saving valuable resources and fabricator time,” comments Thibeault.
Types of Plastic
There are many types of plastic, so which are commonly used for 3D printing in the automotive industry?
Stark finds the most common 3D printed plastic is polyactic acid or polylactide (PLA), due to its low cost and stable physical characteristics as a thermoplastic. “This is mostly used in hobbyist 3D printers since it is not an engineering grade plastic,” he notes.
Flynn says polyamides (PA 12, PA 11) are often used due to their durability and chemical resistance. Additionally, thermoplastic polyurethane or TPU is for flexible applications, and acrylonitrile butadiene styrene (ABS)-like resins are used for tooling.
Nylon, a type of polyamide, is the default standard, according to Walker. He says the automotive industry is familiar with it and it’s the most common in SLS. “The interesting part are the variations which come from powder bed. Adding specific ratios of glass fibers or beads, carbon fiber, stiffening agents, and melt mixing to optimize a material specifically to the mechanical needs.”
ABS is another sought-after plastic because it is a standard commodity, says Thibeault. “However, as 3D printing grows in adoption, the material science follows to satisfy the needs of both OEMs and aftermarket companies. Other plastics include acrylonitrile styrene acrylate or ASA, various nylon polymers (ex. PA6/66, PA12), along with specialty materials like BigRep’s HI-TEMP and HI-TEMP CF, which offer the properties of an ABS without the difficulty.”
Flynn stresses that material choice is just one piece of the overall picture. “You need to ensure optimal processing parameters for each material through software when building your part to maximize their inherent properties while maintaining the consistency and quality that automotive standards demand.”
Features in Demand
There are several functions of 3D printed plastic materials that the automotive industry seeks.
Flynn says thermal resistance, chemical resistance, mechanical strength, fire retardancy (FR), and lightweight design are common demands. “Our software solutions are built specifically to help manufacturers achieve these specifications through precise process control, quality assurance workflows, and compliance tracking. In automotive, it is essential to ensure parts meet stringent standards through integrated quality management systems, like Materialise’s CO-AM Software Platform.”
Walker says it is a budding field. “We have some FR materials for the aerospace industry, and they have been used in production for over a decade. I think there is great potential for their use in the automotive space as well.”
Engaged in Automotive
The automotive industry is a noteworthy early adopter of 3D printing technology. From prototyping to lightweight end-use components, the technology evolves to enable faster development cycles, reduced waste, and greater design flexibility.
As plastic materials advance, so do its use cases.
Nov2025, Industrial Print Magazine
