How 3D Printing is Reshaping the Automotive Industry: 4 Key Digital Manufacturing Trends

Autonomous vehicles, electric cars, and mass customisation are redefining the automotive landscape. To stay competitive in the Industry 4.0 era, manufacturers are accelerating the adoption of 3D printing technologies.

1. 3D Printing Powers Vehicle Electrification

A recent Jabil survey shows that 48 % of automakers aim to become market leaders in electric vehicles. This ambition fuels the growing use of additive manufacturing (AM) across the sector.

As the industry pivots from internal‑combustion engines to EVs, 3D printing offers a rapid development pathway and enables designs that were previously impossible. Lightweighting, driven by generative design tools and AM’s design freedom, is especially critical for EVs, where reduced mass translates directly into longer range and lower battery requirements.

“Generative design and AM will soon be the primary enablers of lighter parts for electric cars,” says Kevin Quinn, GM’s Director of Additive Design and Manufacturing, in an interview with Additive Manufacturing Media.

Weight reduction is vital: heavier vehicles demand larger batteries to meet range targets, and batteries themselves add significant mass. Thus, every kilogram saved in the vehicle or its components extends range and improves performance.

Local Motors’ Olli—an autonomous, 3D‑printed electric shuttle—illustrates this trend. Using the world’s largest 3D printers, ORNL’s Big Area Additive Manufacturing (BAAM) and Thermwood’s Large Scale Additive Manufacturing (LSAM), the company produced most of Olli’s structural components, including the roof and lower body. Olli is now in trials across 13 global locations.

Arcimoto, a U.S. sustainable‑vehicle maker, partners with XponentialWorks to produce Fun Utility Vehicles (FUVs) that feature 3D‑printed parts such as a rear swing arm, knuckle, upper control arm, and brake pedal. These components were redesigned with ParaMatters’ generative design tool, yielding weight savings of 34 % to 49 %. With these redesigns, Arcimoto has achieved 120 lb of the 200‑lb target and plans to reach the final goal soon.

The next decade will be pivotal as the EV sector explores how best to harness 3D printing for sustainable vehicle production.

2. Integrating AM into Automotive Series Production

While 3D printing first gained traction for rapid prototyping, manufacturers are now turning to it for direct part production and tooling. This shift signals a move toward digital mass production.

However, automotive production demands high throughput, low material costs, and deep automation. In addition, evolving demand patterns, supply‑chain dynamics, and the push for mass customisation add complexity.

To meet these challenges, the AM industry is advancing rapidly. Metal binder jetting, for example, offers faster printing speeds than many other metal AM processes, a clear advantage for volume production.

Automakers are also automating their AM workflows: incorporating DfAM (Design for Additive Manufacturing) tools, MES (Manufacturing Execution System) software for traceability, and automated post‑processing rigs. Concurrently, material developers are releasing UV‑stable plastics and automotive‑grade metals like aluminium and steel that meet industry specifications.

A SmarTech report projects automotive AM production revenues to reach nearly $10 billion by the end of this decade.

Although final‑part production with AM is still gaining traction, momentum is expected to accelerate over the next five to ten years as technology matures and new applications emerge.

3. Collaboration Drives AM Industrialisation

Industry and research partners are working to industrialise 3D printing into fully automated production lines for cars. The scale of recent projects highlights this collaborative momentum.

The Industrialisation and Digitalisation of Additive Manufacturing (IDAM) project, led by the BMW Group, brings together twelve partners to build production lines capable of manufacturing at least 50,000 common components per year and more than 10,000 individual or spare parts. The project also aims to halve unit costs for metal 3D‑printed components. IDAM will run for two years, establishing sustainable metal 3D printing in production.

In polymer AM, the POLYLINE project tackles the challenges of integrating 3D‑printed polymers into automotive lines. It focuses on developing new standards, boosting automation, and creating digital data workflows that enhance efficiency across production and supply chains.

Both initiatives, based in Germany, reflect the country’s strong investment in AM for final‑part production.

4. 3D‑Printed Electronics for Connected Cars

Connected vehicles are proliferating a host of sensors and antennas, demanding smaller, more complex electronics. 3D printing for electronics enables these components to be embedded directly into mechanical structures, improving reliability and lifespan while cutting costs and development time.

Researchers at the Institute of Systems and Robotics in Portugal are exploring 3D‑printed touch sensors to replace physical buttons. Neotech AMT GmbH sees potential in 3D‑printing heater patterns for car interiors, reducing weight, part count, and assembly steps.

Although 3D‑printed electronic components are not yet mainstream, the widespread adoption of 3D printing for metal and plastic parts in the automotive sector suggests that the next wave of lightweight, complex electronics will follow.

3D Printing in Automotive: On the Brink of Change

As vehicles become smarter and more autonomous, automakers and suppliers face transformative shifts that drive further 3D‑printing adoption. The technology offers unmatched flexibility, enabling the creation of parts that traditional processes cannot produce.

Strategic partnerships with AM companies and collaborative industrialisation projects are shaping the future of automotive manufacturing. While the full impact remains to be demonstrated, the vision and scope of these initiatives signal a bright future for 3D printing in the industry.