3D Printing Accelerates EV Body Design and Production

In a recent feature for Automotive Product Finder magazine, we shared insights into how 3D printing is reshaping electric vehicle (EV) development.

Electric vehicles demand a distinct body architecture compared to internal combustion engine (ICE) cars. In this interview, Swapnil Sansare, CEO and Founder of Divide by Zero Technologies (DBZ), explains how automakers are harnessing additive manufacturing (AM) to streamline body design and accelerate time‑to‑market.

What solutions does DBZ offer to OEMs?

Today’s automotive landscape is highly volatile, with assembly lines needing rapid adaptation to regulatory changes, market feedback, and innovation cycles. DBZ specializes in on‑demand 3D‑printed jig and fixture fabrication, dramatically cutting fixture costs and cutting production lead times. Our flagship AION 500 MK3 platform can produce parts up to ten times faster than traditional plastic extrusion printers.

How is additive manufacturing expediting body design?

Automotive has long been the leading adopter of AM, initially limited to first‑level prototyping. Recent advances now enable full‑scale production integration, offering superior design flexibility, cost savings, and rapid iteration. The technology allows for complex, lightweight structures that reduce overall vehicle weight and simplify assembly. With a growing range of affordable printers and consumables, AM’s accessibility continues to expand, making it an essential tool for modern vehicle development.

Why is 3D printing vital for EVs?

EVs feature a simpler powertrain and fewer moving parts than ICE vehicles, creating opportunities for lightweight, streamlined body designs. AM supports this by enabling part simplification, reducing inventory through digital libraries, and shortening assembly cycles—all of which lower production costs. A notable example is Chinese manufacturer XEV, which built an electric car using 57 3D‑printed plastic parts. The approach eliminated the need for expensive tooling, reduced time‑to‑market, and allowed for on‑demand customization such as swapping a passenger seat for a storage box. DBZ is pursuing similar innovations to transform India’s automotive sector.

Discover more about the AION 500 MK3.

Article courtesy – Automotive Product Finder